Title of Invention

"OPTICAL ELEMENT ADAPTED TO POSSESS LIGHT INFLUENCING PROPERTY "

Abstract Described are optical elements made of a substrate and a curable film-forming composition applied to at least a portion of the substrate to form a coating thereon. The curable film-forming composition comprises: i) a resinous material comprising a monomer, oligomer, and/or polymer containing reactive functional groups; ii) a curing agent having two or more reactive functional groups that are reactive with functional groups in the resinous material of i); and iii) a material different from i) and ii), comprising a blocked isocyanate group blocked with a blocking agent capable of deblocking at a low temperature. The material of iii) is present in the curable film-forming composition at least in an amount sufficient to improve adhesion between the curable film-forming composition and the substrate and/or a superposed coating compared to a substantially identical optical element that does not comprise the material of iii) in the curable film-forming composition.
Full Text -1-
OPTICAL ELEMENTS THAT INCLUDE CURABLE FILM-FORMING
COMPOSITIONS CONTAINING BLOCKED ISOCYANATE ADHESION
PROMOTERS
FIELD OF THE INVENTION
[0001] The present invention relates to optical elements comprising
substrates coated with curable film-forming compositions containing blocked
isocyanate adhesion promoters.
BACKGROUND OF THE INVENTION
[0002] Optical elements that provide acceptable imaging qualities while
maintaining durability and abrasion resistance are sought for a variety of
applications, such as windshields, sunglasses, fashion lenses, nonprescription
and prescription lenses, sport masks, face shields and goggles.
Responsive to that need, coated optical elements have been developed.
[0003] However, often the coatings lack sufficient adhesion to a substrate to
provide long wear. Coatings such as photochromic coatings and protective
tie-layer coatings have been developed containing adhesion promoters such
as epoxides and aminoalkyltrialkoxysilanes to enhance adhesion of coatings
to the substrate and/or to subsequently applied coatings. However, such
adhesion promoters have highly reactive functional groups that may lead to
instability and reduced shelf life of coating compositions. Blocked isocyanates
have also been used, but when the deblocking temperature of the blocking
agent exceeds the curing temperature of the resinous components, the
adhesion promoters may not be as effective as necessary.
[0004] There is a need in the art to develop optical articles containing coating
compositions with adhesion promoters that will be effective at improving
adhesion at or below curing temperatures, yet will not interfere with
composition shelf life.
SUMMARY OF THE INVENTION
[0005] In accordance with the present invention, an optical article adapted to
possess a light influencing property is provided, comprising:
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a) a substrate; and
b) a curable film-forming composition applied to at least a
portion of the substrate to form a coating thereon. The curable film-forming
composition comprises:
i) a resinous material comprising a monomer, oligomer,
and/or polymer containing reactive functional groups;
ii) a curing agent having two or more reactive functional
groups that are reactive with functional groups in the resinous material of i);
and
iii) a material different from i) and ii), comprising a blocked
isocyanate group and another different functional group capable of reacting
with functional groups on the resinous material of i), functional groups on the
curing agent of ii), functional groups on a superposed coating, and/or
functional groups on the substrate. In one embodiment, the isocyanate group
is blocked with a blocking agent capable of deblocking at a temperature as
low as 100°C. Alternatively, the blocking agent is capable of deblocking at or
below a temperature at which any of the functional groups on the material of
iii), functional groups on the resinous material of i), functional groups on the
curing agent of ii), functional groups on a superposed coating, and/or
functional groups on the substrate react w/ each other. The material of iii) is
present in the curable film-forming composition at least in an amount sufficient
to improve adhesion between the curable film-forming composition and the
substrate and/or a superposed coating compared to a substantially identical
optical element that does not comprise the material of iii) in the curable filmforming
composition.
DETAILED DESCRIPTION OF THE INVENTION
[0006] It is noted that, as used in this specification and the appended claims,
the singular forms "a," "an," and "the" include plural referents unless expressly
and unequivocally limited to one referent.
[0007] For the purposes of this specification, unless otherwise indicated, all
numbers expressing quantities of ingredients, reaction conditions, and other
parameters used in the specification and claims are to be understood as
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being modified in all instances by the term "about." Accordingly, unless
indicated to the contrary, the numerical parameters set forth in the following
specification and attached claims are approximations that may vary
depending upon the desired properties to be obtained by the present
invention. At the very least, and not as an attempt to limit the application of
the doctrine of equivalents to the scope of the claims, each numerical
parameter should at least be construed in light of the number of reported
significant digits and by applying ordinary rounding techniques.
[0008] All numerical ranges herein include all numerical values and ranges of
all numerical values within the recited numerical ranges. Notwithstanding that
the numerical ranges and parameters setting forth the broad scope of the
invention are approximations, the numerical values set forth in the specific
examples are reported as precisely as possible. Any numerical value,
however, inherently contain certain errors necessarily resulting from the
standard deviation found in their respective testing measurements.
[0009] The various embodiments and examples of the present invention as
presented herein are each understood to be non-limiting with respect to the
scope of the invention.
[0010] As used in the following description and claims, the following terms
have the indicated meanings:
[0011] The terms "acrylic" and "acrylate" are used interchangeably (unless to
do so would alter the intended meaning) and include acrylic acids,
anhydrides, and derivatives thereof, such as their Ci-Cs alkyl esters, lower
alkyl-substituted acrylic acids, e.g., C-i-C5 substituted acrylic acids, such as
methacrylic acid, ethacrylic acid, etc., and their CrCs alkyl esters, unless
clearly indicated otherwise. The terms "(meth)acrylic" or "(meth)acrylate" are
intended to cover both the acrylic/acrylate and methacrylic/methacrylate forms
of the indicated material, e.g., a (meth)acrylate monomer.
[0012] The term "cure", "cured" or similar terms, as used in connection with a
cured or curable composition, e.g., a "cured composition" of some specific
description, means that at least a portion of the polymerizable and/or
crosslinkable components that form the curable composition is at least
partially polymerized and/or crosslinked. In one embodiment, the degree of
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crosslinking, can range from 5% to 100% of complete crosslinking. In
alternate embodiments, the degree of crosslinking can range from 35% to
85%, e.g., 50% to 85%, of full crosslinking. The degree of crosslinking can
range between any combination of the previously stated values, inclusive of
the recited values.
[0013] The term "curable", as used for example in connection with a curable
film-forming composition, means that the indicated composition is
polymerizable or cross linkable, e.g., by means that include, but are not
limited to, thermal, catalytic, electron beam, chemical free-radical initiation,
and/or photoinitiation such as by exposure to ultraviolet light or other actinic
radiation.
[0014] The term "light influencing function", "light influencing property" or
terms of like import means that the indicated material, e.g., coating, film,
substrate, etc., is capable of modifying by absorption (or filtering) of incident
light radiation, e.g., visible, ultraviolet (UV) and/or infrared (IR) radiation that
impinges on the material. In alternate embodiments, the light influencing
function can be light polarization, e.g., by means of a polarizer and/or dichroic
dye; a change in light absorption properties, e.g., by use of a chromophore
that changes color upon exposure to actinic radiation, such as a photochromic
material; transmission of only a portion of the incident light radiation, e.g., by
use of a fixed tint such as a conventional dye; or by a combination of one or
more of such light influencing functions.
[0015] The term "adapted to possess at least one light influencing property",
as used for example in connection with a rigid optical substrate, means that
the specified item is capable of having the light influencing property
incorporated into or appended to it. For example, a plastic matrix that is
adapted to possess a light influencing property means that the plastic matrix
has sufficient internal free volume to accommodate internally a photochromic
dye or tint. The surface of such a plastic matrix may alternatively be capable
of having a photochromic or tinted layer, film or coating appended to it, and/or
is capable of having a polarizing film appended to it.
[0016] The terms "on", "appended to", "affixed to", "bonded to", "adhered to",
or terms of like import means that the designated item, e.g., a coating, film or
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layer, is either directly connected to (superimposed on) the object surface, or
indirectly connected to the object surface, e.g., through one or more other
coatings, films or layers (superposed on).
[0017] The term "ophthalmic" refers to elements and devices that are
associated with the eye and vision, such as but not limited to, lenses for
eyewear, e.g., corrective and non-corrective lenses, and magnifying lenses.
[0018] The term "optical quality", as used for example in connection with
polymeric materials, e.g., a "resin of optical quality" or "organic polymeric
material of optical quality" means that the indicated material, e.g., a polymeric
material, resin, or resin composition, is or forms a substrate, layer, film or
coating that can be used as an optical article, such as an ophthalmic lens, or
in combination with an optical article.
[0019] The term "rigid", as used for example in connection with an optical
substrate, means that the specified item is self-supporting.
[0020] The term "optical substrate" means that the specified substrate exhibits
a light transmission value (transmits incident light) of at least 4 percent and
exhibits a haze value of less than 1 percent, e.g., less than 0.5 percent, when
measured at 550 nanometers by, for example, a Haze Card Plus Instrument.
Optical substrates include, but are not limited to, optical articles such as
lenses, optical layers, e.g., optical resin layers, optical films and optical
coatings, and optical substrates having a light influencing property.
[0021] The term "photochromic receptive" means that the indicated item has
sufficient free volume to permit photochromic material(s) incorporated within it
to transform from its colorless form to its colored form (and then revert to its
colorless form) to the degree required for commercial optical applications.
[0022] The term "tinted", as used for example in connection with ophthalmic
elements and optical substrates, means that the indicated item contains a
fixed light radiation absorbing agent, such as but not limited to, conventional
coloring dyes, infrared and/or ultraviolet light absorbing materials on or in the
indicated item. The tinted item has an absorption spectrum for visible
radiation that does not vary significantly in response to actinic radiation.
[0023] The term "non-tinted", as used for example in connection with
ophthalmic elements and optical substrates, means that that the indicated
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item is substantially free of fixed light radiation absorbing agents. The nontinted
item has an absorption spectrum for visible radiation that does not vary
significantly in response to actinic radiation.
[0024] The term "actinic radiation" includes light with wavelengths of
electromagnetic radiation ranging from the ultraviolet ("UV") light range,
through the visible light range, and into the infrared range. Actinic radiation
which can be used to cure coating compositions used in the present invention
generally has wavelengths of electromagnetic radiation ranging from 150 to
2,000 nanometers (nm), from 180 to 1,000 nm, or from 200 to 500 nm. In one
embodiment, ultraviolet radiation having a wavelength ranging from 10 to 390
nm can be used. Examples of suitable ultraviolet light sources include
mercury arcs, carbon arcs, low, medium or high pressure mercury lamps,
swirl-flow plasma arcs and ultraviolet light emitting diodes. Suitable ultraviolet
light-emitting lamps are medium pressure mercury vapor lamps having
outputs ranging from 200 to 600 watts per inch (79 to 237 watts per
centimeter) across the length of the lamp tube.
[0025] The term "tinted photochromic", as used for example in connection
with ophthalmic elements and optical substrates, means that the indicated
item contains a fixed light absorbing agent and a photochromic material. The
indicated item has an absorption spectrum for visible radiation that varies in
response to actinic radiation and is thermally reversible when the actinic
radiation is removed. For example, the tinted photochromic item may have a
first characteristic of the light absorbing agent, e.g., a coloring tint, and a
second color characteristic of the combination of the light absorbing agent and
the activated photochromic material when the photochromic material is
exposed to actinic radiation.
[0026] The term "dichroic material', "dichroic dye" or terms of like import
means a material/dye that absorbs one of two orthogonal plane-polarized
components of transmitted radiation more strongly than the other. Nonlimiting
examples of dichroic materials include indigoids, thioindigoids,
merocyanines, indans, azo and poly(azo) dyes, benzoquinones,
naphthoquinones, anthraquinones, (poly)anthraquinones,
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anthrapyrimidinones, iodine and iodates. The term "dichroic" is synonymous
with "polarizing" or words of like import.
[0027] The term "dichroic photochromic" means a specified material or article
that exhibits both dichroic and photochromic properties. In alternate nonlimiting
embodiments, the specified material can include both photochromic
dyes/compounds and dichroic dyes/compounds, or single dyes/compounds
that possess both photochromic and dichroic properties.
[0028] The term "transparent", as used for example in connection with a
substrate, film, material and/or coating, means that the indicated substrate,
coating, film and/or material has the property of transmitting light without
appreciable scattering so that objects lying beyond are entirely visible.
[0029] The phrase "an at least partial film" means an amount of film covering
at least a portion, up to the complete surface of the substrate. As used
herein, a "film" may be formed by a sheeting type of material or a coating type
of material. For example, a film may be an at least partially cured polymeric
sheet or an at least partially cured polymeric coating of the material indicated.
The phrase "at least partially cured" means a material in which from some to
all of the curable or cross-linkable components are cured, crosslinked and/or
reacted.
[0030] The term "photochromic amount" means that a sufficient amount of
photochromic material is used to produce a photochromic effect discernible to
the naked eye upon activation. The particular amount used depends often
upon the intensity of color desired upon irradiation thereof and upon the
method used to incorporate the photochromic materials. Typically, in another
non-limiting embodiment, the more photochromic incorporated, the greater is
the color intensity up to a certain limit. There is a point after which the
addition of any more material will not have a noticeable effect, although more
material can be added, if desired.
[0031] The term "superposed" describes a coating applied on top of or
subsequent to the curable film-forming composition of b), such that at least a
portion of the curable film-forming composition of b) lies between the
substrate and the superposed coating.
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[0032] According to the present invention, an optical element adapted to
possess a light influencing property is provided, comprising:
a) a substrate; and
b) a curable film-forming composition applied to at least a
portion of the substrate to form a coating thereon. The curable film-forming
composition in turn comprises:
i) a resinous material comprising a monomer, oligomer,
and/or polymer containing reactive functional groups;
ii) a curing agent having two or more reactive functional
groups that are reactive with functional groups in the resinous material of i);
and
iii) a material different from i) and ii), comprising a blocked
isocyanate group and another different functional group capable of reacting
with functional groups on the resinous material of i), functional groups on the
curing agent of ii), functional groups on a superposed coating, and/or
functional groups on the substrate. The isocyanate group is blocked with a
blocking agent. In one embodiment, the blocking agent is capable of
deblocking at a temperature as low as 100°C. In a separate embodiment,
often when the curable film-forming composition is thermally curable, the
blocking agent is capable of deblocking at or below a temperature at which
any of the functional groups on the material of iii), functional groups on the
resinous material of i), functional groups on the curing agent of ii), functional
groups on a superposed coating, and/or functional groups on the substrate
react w/ each other. Additionally, the material of iii) is present in the curable
film-forming composition at least in an amount sufficient to improve adhesion
between the curable film-forming composition and the substrate and/or a
superposed coating compared to a substantially identical optical element that
does not contain the material of iii) in the curable film-forming composition.
[0033] Optical elements of the present invention include ophthalmic articles
such as piano (without optical power) and vision correcting (prescription)
lenses (finished and semi-finished) including multifocal lenses (bifocal, trifocal,
and progressive lenses); and ocular devices such as contact lenses and
intraocular lenses, sun lenses, fashion lenses, sport masks, face shields and
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goggles. The optical element may also be chosen from glazings such as
windows and vehicular transparencies such as automobile windshields and
side windows.
[0034] The optical elements of the present invention are adapted to possess a
light influencing property. Such properties may be of more than one type and
may be imparted to any of the components of the optical element, including
the substrate, the curable film-forming composition, and/or any superposed
coatings.
[0035] The substrate a) used in the present invention comprises an optical
substrate and may be chosen from, inter alia, mineral glass, ceramic, solgel,
and polymeric organic materials. The substrate may be rigid, i. e., capable of
maintaining its shape and supporting the applied curable film-forming
composition. The optical substrate, including any coatings or treatments
applied thereto, may be adapted to possess a light influencing property as
discussed above. The light influencing property may be of more than one
type and may be integral to (i. e., incorporated into) the substrate, for
example, by imbibition or casting of a light influencing compound into the
substrate matrix, or a light influencing compound may be contained in a
coating or treatment applied to a surface of the substrate. In a particular
embodiment of the present invention the substrate is a polymeric organic
material such as an optically clear polymerizate, e.g., material suitable for
optical applications, such as ophthalmic articles. Such optically clear
polymerizates have a refractive index that may vary widely. Examples include
polymerizates of optical resins such as thermoplastic polycarbonate and
optical resins sold by PPG Industries, Inc. as TRIVEX® monomer composition
and under the CR- designation, e.g., CR-39® monomer composition. High
refractive index polythiourethane substrates available from Mitsui Chemicals
Co., Ltd., under the names MR-6, MR-7, MR-8, and MR-10 are also suitable.
Non-limiting examples of other suitable substrates are disclosed in U.S.
Patent Publication 2004/0096666 in paragraphs [0061] and [0064] to [0081],
incorporated herein by reference.
[0036] The substrate used in the optical article of the present invention may
comprise polymeric organic material chosen from thermoplastic material,
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thermosetting material and mixtures thereof. Such materials are described in
the Kirk-Othmer Encyclopedia of Chemical Technology. Fourth Edition,
Volume 6, pages 669 to 760. Thermoplastic materials can be made
substantially thermoplastic or thermosetting by the appropriate chemical
modification, as known to those skilled in the art.
[0037] Further examples of optical resins that may be used as substrates in
the present invention include the resins used to form hard and soft contact
lenses such as are disclosed in U.S. Patent No. 5,166,345, column 11, line
52, to column 12, line 52, soft contact lenses with high moisture content as
described in U.S. Patent No. 5,965,630 and extended wear contact lenses as
described in U.S. Patent No. 5,965,631, which disclosures related to optical
resins for contact lenses are incorporated herein by reference.
[0038] In certain embodiments, the substrate may include a coating or film on
the surface thereof, wherein the coating or film imparts a light influencing
property and/or provides protection to the substrate from abrasion or other
damage. Examples of suitable abrasion resistant coatings include those
disclosed in published U. S. Patent Application No. 2004/0207809,
paragraphs [0205]-[0249], incorporated herein by reference. Suitable
coatings designed to provide impact resistance include those disclosed in U.
S. Patent No. 5,316,791, col. 3, line 7-col. 7, line 35, incorporated herein by
reference. Other suitable coatings and films are discussed in more detail
below.
[0039] The curable film-forming composition of b) may be cured using any
known means, such as thermally or by actinic radiation. The film-forming
composition comprises:
i) a resinous material comprising a monomer, oligomer,
and/or polymer containing reactive functional groups;
ii) a curing agent having two or more reactive functional
groups that are reactive with functional groups in the resinous material of i);
and
iii) a material different from i) and ii), comprising a blocked
isocyanate group and at least one other different functional group capable of
reacting with functional groups on the resinous material of i), functional groups
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on the curing agent of ii), functional groups on a superposed coating, and/or
functional groups on the substrate. The curable film-forming composition
used in the optical element of the present invention may be in any physical
form, most often solventborne or waterborne.
[0040] The resinous material of i) may comprise one or more monomers,
wherein at least one monomer contains reactive functional groups. Suitable
monomers include ethylenically unsaturated monomers, for example, vinyl
monomers and/or (meth)acrylic monomers; i. e., monomers of acrylic or
methacrylic acid or esters thereof, such as aliphatic alkyl esters containing
from 1 to 30, and often 4 to 18 carbon atoms in the alkyl group. Suitable
esters include methyl (meth)acrylate, ethyl (meth)acrylate, isopropyl
(meth)acrylate, n-butyl(meth)acrylate, isobutyl (meth)acrylate, 2-ethylhexyl
(meth)acrylate, 2-hydroxyethyl (meth)acrylate, glycidyl (meth)acrylate,
diethylene glycol (meth)acrylate, 2,2-dimethyl-3-hydroxypropyl-2,2-dimethyl-3-
hydroxypropionate, isobornyl (meth)acrylate, tetrahydrofurfuryl (meth)acrylate,
(meth)acrylates derived from aromatic glycidyl ethers such as bisphenol A
diglycidyl ethers and aliphatic diglycidyl ethers, and styrene-type monovinyl
aromatic compounds such as styrene, methylstyrene, ethyl styrene and
chlorostyrene.
[0041] Useful hydroxyl functional monomers include hydroxyalkyl acrylates
and methacrylates, typically having 2 to 4 carbon atoms in the hydroxyalkyl
group, such as hydroxyethyl acrylate, hydroxypropyl acrylate, 4-hydroxybutyl
acrylate, hydroxy functional adducts of caprolactone and hydroxyalkyl
acrylates, and corresponding methacrylates, as well as the beta-hydroxy ester
functional monomers described below. N-(alkoxymethyl)acrylamides and N-
(alkoxymethyl)methacrylamides are also suitable.
[0042] Beta-hydroxy ester functional monomers can be prepared from
ethylenically unsaturated, epoxy functional monomers and carboxylic acids
having from about 13 to about 20 carbon atoms, or from ethylenically
unsaturated acid functional monomers and epoxy compounds containing at
least 5 carbon atoms which are not polymerizable with the ethylenically
unsaturated acid functional monomer.
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[0043] Useful ethylenically unsaturated, epoxy functional monomers used to
prepare the beta-hydroxy ester functional monomers include, but are not
limited to, glycidyl acrylate, glycidyl methacrylate, allyl glycidyl ether, methallyl
glycidyl ether, 1:1 (molar) adducts of ethylenically unsaturated
monoisocyanates with hydroxy functional monoepoxides such as glycidol, and
glycidyl esters of polymerizable polycarboxylic acids such as maleic acid.
Glycidyl acrylate and glycidyl methacrylate are preferred. Examples of
carboxylic acids include, but are not limited to, saturated monocarboxylic
acids such as isostearic acid and aromatic unsaturated carboxylic acids.
[0044] Useful ethylenically unsaturated acid functional monomers used to
prepare the beta-hydroxy ester functional monomers include monocarboxylic
acids such as acrylic acid, methacrylic acid, crotonic acid; dicarboxylic acids
such as itaconic acid, maleic acid and fumaric acid; and monoesters of
dicarboxylic acids such as monobutyl maleate and monobutyl itaconate. The
ethylenically unsaturated acid functional monomer and epoxy compound are
typically reacted in a 1:1 equivalent ratio. The epoxy compound does not
contain ethylenic unsaturation that would participate in free radical-initiated
polymerization with the unsaturated acid functional monomer. Useful epoxy
compounds include 1,2-pentene oxide, styrene oxide and glycidyl esters or
ethers, usually containing from 8 to 30 carbon atoms, such as butyl glycidyl
ether, octyl glycidyl ether, phenyl glycidyl ether and para-(tertiary butyl) phenyl
glycidyl ether. Commonly used glycidyl esters include those of the structure:
O
CH2—CH—CH2—O—C—R
O
[0045] where R is a hydrocarbon radical containing from about 4 to about 26
carbon atoms. Often, R is a branched hydrocarbon group having from about
8 to about 10 carbon atoms, such as neopentanoate, neoheptanoate or
neodecanoate. Suitable glycidyl esters of carboxylic acids include VERSATIC
ACID 911 and CARDURA E, each of which are commercially available from
Shell Chemical Co.
[0046] Carbamate functional monomers, such as a carbamate functional alkyl
ester of (meth)acrylic acid, may be used. Other useful carbamate functional
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monomers are disclosed in U.S. Patent No. 5,098,947, which is incorporated
herein by reference. Other useful carbamate functional monomers are
disclosed in U.S. Patent No. 5,098,947, which is incorporated herein by
reference.
[0047] Amide functional monomers are suitable for use as the resinous
material i). Likewise, other functional groups may be incorporated as desired
using suitably functional monomers if available or conversion reactions as
necessary.
[0048] Actinic radiation-curable compositions generally contain at least one
free radical photoinitiator. When the composition includes cationic initiated
epoxy monomer(s), the formulation will also contain at least one cationic
photoinitiator. The photoinitiator will be present in amounts sufficient to
initiate and sustain the curing of the composition, i.e., an initiating amount.
Photoinitiators are typically used in the least amount necessary to obtain
initiation of the curing process. Generally, the photoinitiator(s) is present in
amounts of from 0.1 to 10 weight percent. In alternate embodiments, the
photoinitiator is present in amounts of from 0.5 to 6 weight percent, e.g., from
1 to 4 weight percent, based on the total weight of the photoinitiated
polymerizable components in the curable composition. Free radical
photoinitiators are well known to those skilled in the art. Examples of
commercial photoinitiators can be found in column 10, lines 38-43 of U.S.
Patent 5,910,375, which disclosure is hereby incorporated herein by
reference.
[0049] Cationic photoinitiators can be used in conjunction with the free-radical
photoinitiators. Generally, cationic initiators are used with abstraction type
photoinitiators, hydrogen donor materials such as butyryl choline
triphenylbutyl borate or combinations of such materials. Typical cationic
photoinitiators are onium salts, which are described in U.S. Patent 5,639,802,
column 8, line 59 to column 10, line 46, which disclosure is hereby
incorporated herein by reference. Non-limiting examples of such initiators
include 4,4'-dimethyldiphenyliodonium tetrafluoroborate, phenyl-4-
octyloxyphenyl phenyliodonium hexafluoroantimonate, dodecyldiphenyl
iodonium hexafluoroantimonate, [4-[(2-tetradecanol)oxy]phenyl]phenyl
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iodonium hexafluoroantimonate, triaryl sulfonium hexafluoroantimonate salts
and triaryl sulfonium hexafluorophosphate salts, e.g., triphenylsulfonium salt
of phosphorous hexafluoride. Mixtures of cationic initiators can also be used.
[0050] The resinous material of i) may also comprise oligomers and/or
polymers, selected from acrylic polymers, polyesters, polyurethanes,
polycarbonates, and polyethers. Generally these oligomers and polymers can
be any of these types made by any method known to those skilled in the art.
The functional groups on the resinous material may be selected from, inter
alia, carboxylic acid groups, amine groups, epoxide groups, hydroxyl groups,
thiol groups, carbamate groups, amide groups, urea groups, acrylate groups
and mercaptan groups.
[0051] Suitable acrylic polymers include copolymers of acrylic acid or
methacrylic acid, and/or one or more alkyl esters of acrylic acid or methacrylic
acid, optionally together with one or more other polymerizable ethylenically
unsaturated monomers. Useful alkyl esters of acrylic acid or methacrylic acid
include aliphatic alkyl esters containing from 1 to 30, and often 4 to 18 carbon
atoms in the alkyl group. Non-limiting examples include methyl methacrylate,
ethyl methacrylate, butyl methacrylate, ethyl acrylate, butyl acrylate, and 2-
ethyl hexyl acrylate. Suitable other copolymerizable ethylenically unsaturated
monomers include vinyl aromatic compounds such as styrene and vinyl
toluene; nitriles such as acrylonitrile and methacrylonitrile; vinyl and vinylidene
halides such as vinyl chloride and vinylidene fluoride and vinyl esters such as
vinyl acetate.
[0052] The acrylic copolymer can include hydroxyl functional groups, which
are often incorporated into the polymer by including one or more hydroxyl
functional monomers in the reactants used to produce the copolymer. Useful
hydroxyl functional monomers include those mentioned above. The acrylic
polymer can also be prepared with N-(alkoxymethyl)acrylamides and N-
(alkoxymethyl)methacrylamides.
[0053] Carbamate functional groups can be included in the acrylic polymer by
copolymerizing the acrylic monomers with a carbamate functional vinyl
monomer, such as a carbamate functional alkyl ester of methacrylic acid.
Alternatively, carbamate functionality may be introduced into the acrylic
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polymer by reacting a hydroxyl functional acrylic polymer with a low molecular
weight carbamate functional material, such as can be derived from an alcohol
or glycol ether, via a transcarbamoylation reaction. In this reaction, a low
molecular weight carbamate functional material derived from an alcohol or
glycol ether is reacted with the hydroxyl groups of the acrylic polyol, yielding a
carbamate functional acrylic polymer and the original alcohol or glycol ether.
The low molecular weight carbamate functional material derived from an
alcohol or glycol ether may be prepared by reacting the alcohol or glycol ether
with urea in the presence of a catalyst. Suitable alcohols include lower
molecular weight aliphatic, cycloaliphatic, and aromatic alcohols such as
methanol, ethanol, propanol, butanol, cyclohexanol, 2-ethylhexanol, and 3-
methylbutanol. Suitable glycol ethers include ethylene glycol methyl ether
and propylene glycol methyl ether. Propylene glycol methyl ether and
methanol are most often used. Other carbamate functional monomers as
known to those skilled in the art may also be used.
[0054] Amide functionality may be introduced to the acrylic polymer by using
suitably functional monomers in the preparation of the polymer, or by
converting other functional groups to amido- groups using techniques known
to those skilled in the art. Likewise, other functional groups may be
incorporated as desired using suitably functional monomers if available or
conversion reactions as necessary.
[0055] Acrylic polymers can be prepared via aqueous emulsion
polymerization techniques and used directly in the preparation of aqueous
coating compositions, or can be prepared via organic solution polymerization
techniques for solventborne compositions. When prepared via organic
solution polymerization with groups capable of salt formation such as acid or
amine groups, upon neutralization of these groups with a base or acid the
polymers can be dispersed into aqueous medium. Generally any method of
producing such polymers that is known to those skilled in the art utilizing art
recognized amounts of monomers can be used.
[0056] Besides acrylic polymers, the resinous material of i) may be an alkyd
resin or a polyester oligomer and/or polymer. Such materials may be
prepared in a known manner by condensation of polyhydric alcohols and
-16-
polycarboxylic acids. Suitable polyhydric alcohols include, but are not limited
to, ethylene glycol, propylene glycol, butylene glycol, 1,6-hexylene glycol,
neopentyl glycol, diethylene glycol, glycerol, trimethylol propane, and
pentaerythritol. Suitable polycarboxylic acids include, but are not limited to,
succinic acid, adipic acid, azelaic acid, sebacic acid, maleic acid, fumaric acid,
phthalic acid, tetrahydrophthalic acid, hexahydrophthalic acid, and trimellitic
acid. Besides the polycarboxylic acids mentioned above, functional
equivalents of the acids such as anhydrides where they exist or lower alkyl
esters of the acids such as the methyl esters may be used. Where it is
desired to produce air-drying alkyd resins, suitable drying oil fatty acids may
be used and include, for example, those derived from linseed oil, soya bean
oil, tall oil, dehydrated castor oil, or tung oil.
[0057] Unsaturated polyester resins are well known to those skilled in the art
and can be prepared by the reaction of one or more polyols with one or more
polycarboxylic acids (saturated and unsaturated), with olefinic unsaturation
being provided by one or more of the reactants, usually the polycarboxylic
acid. The polyester resin will generally have a number average molecular
weight of from 1000 to 5000.
[0058] Non-limiting examples of unsaturated polycarboxylic acids, e.g.,
dicarboxylic acids, include but are not limited to, maleic, fumaric, citraconic,
itaconic and meconic acids, their anhydrides and their lower alkyl esters or
acid halides. Non-limiting examples of saturated polycarboxylic acids include
aliphatic dicarboxylic acids such as malonic, succinic, glutaric, adipic, suberic,
azelaic, pimelic and sebacic acids; aromatic acids such as orthophthalic,
terephthalic, isophthalic acids and the anhydrides of such aromatic acids,
such as phthalic anhydride and maleic anhydride, and the lower alkyl esters
or acid halides of these acids or mixtures thereof.
[0059] Non-limiting examples of polyols include ethylene glycol, propylene
glycol, butylene glycols, neopentyl glycol, dipropylene glycol and the
poly(ethylene glycol)s, such as diethylene glycol, triethylene glycol,
tetraethylene glycol and mixtures thereof.
[0060] The polyester resin may also contain other copolymerizable monomers
such as allylic esters, acrylate monomers and mixtures thereof. Non-limiting
-17-
examples of allylic esters include diallyl phthalate, diethylene glycol bis(allyl
carbonate), triallyl cyanurate, allyl acrylate and diallyl maleate. Non-limiting
examples of acrylate monomers include monoacrylates, diacrylates,
triacrylates, tetraacrylates, pentaacrylates and higher polyfunctional acrylates,
which include methyl methacrylate, ethylene glycol diacrylate, ethylene glycol
dimethacrylate, polyethylene glycol diacrylate, polyethylene glycol
dimethacrylate, 1,6-hexanedioldiacrylate, ethoxylated bisphenol A diacrylate,
ethoxylated bisphenol A dimethacrylate, trimethylolpropane polyoxyethylene
triacrylate, dipentaerythritol pentaacrylate and bis(4-
methacrylolylthiophenyl)sulfide.
[0061] The allylic ester may represent from 1 to 20 weight percent of the
polyester resin composition. The acrylate monomer may represent from 1 to
50 weight percent of the polyester composition. The polyester composition
can be cured by incorporating conventional photoinitiators in the composition,
followed by irradiating the composition with radiation, e.g., ultraviolet light.
Non-limiting examples of polyester compositions can be found in Tables 2, 3,
5, 7 and 8 of U.S. Patent 6,863,848, which compositions are incorporated
herein by reference. Further details of these compositions and their curing
can be found in column 16, line 11 through column 21, line 48 of U.S. Patent
6,863,848 B2, which disclosure is incorporated herein by reference.
[0062] Another non-limiting example of a suitable resinous material of i) is a
composition comprising an unsaturated polyester resin, an ethylenically
unsaturated ester monomer, an optional vinyl monomer and a free radical
polymerization catalyst. Such compositions are described in column 6, line 61
to column 10, line 54 of U.S. Patent 5,319,007, which disclosure is
incorporated by reference. The unsaturated polyester resin is derived from
the interaction of saturated or unsaturated dicarboxylic acids with polyhydric
alcohols.
[0063] The base polyester resin generally has a molecular weight of from
1500 to 5200 with an average molecular weight of 2470 and a Brookfield
viscosity at 25 °C of 440 centipoises. In addition to the base polyester, a
flexible polyester can be included optionally.
-18-
[0064] The ethylenically unsaturated ester can be an aromatic ester
represented by the following general formula:
CH2=C(A)-C(0)-0-[( CH2)m-0]n-Ar(R)
wherein A comprises a Cns alkyl, Ar comprises a phenylene molecule, R
comprises a C-I-B alkyl, m comprises an integer of 1 to 6, and n comprises an
integer of 1 to 12, or the unsaturated ester can be an ester of an acrylic or
methacrylic acid. Non-limiting examples of such ethylenically unsaturated
esters include methyl acrylate, methyl methacrylate, phenoxyethyl acrylate,
phenoxyethyl methacrylate, methoxyethyl methacrylate, methoxyethyl
acrylate, ethoxyethyl methacrylate, and ethoxyethyl acrylate.
[0065] Carbamate functional groups may be incorporated into the polyester
by first forming a hydroxyalkyl carbamate which can be reacted with the
polyacids and polyols used in forming the polyester. The hydroxyalkyl
carbamate is condensed with acid functionality on the polyester, yielding
terminal carbamate functionality. Carbamate functional groups may also be
incorporated into the polyester by reacting terminal hydroxyl groups on the
polyester with a low molecular weight carbamate functional material via a
transcarbamoylation process similar to the one described above in connection
with the incorporation of carbamate groups into the acrylic polymers, or by
reacting isocyanic acid with a hydroxyl functional polyester.
[0066] Other functional groups such as ethylenic unsaturation, amine, amide,
thiol, and urea may be incorporated into the polyester or alkyd resin as
desired using suitably functional reactants if available, or conversion reactions
as necessary to yield the desired functional groups. Such techniques are
known to those skilled in the art.
[0067] Polyurethanes can also be used as the resinous material of i). Among
the polyurethanes which can be used are polyurethane polyols which
generally are prepared by reacting the polyester polyols or acrylic polyols
such as those mentioned above with a polyisocyanate such that the OH/NCO
equivalent ratio is greater than 1:1 so that free hydroxyl groups are present in
the product. The organic polyisocyanate which is used to prepare the
polyurethane polyol can be an aliphatic polyisocyanate, which is typically
-19-
used, or an aromatic polyisocyanate or a mixture of the two. Diisocyanates
are typically used, although higher polyisocyanates can be used in place of or
in combination with diisocyanates. Examples of suitable aromatic
diisocyanates are 4,4'-diphenylmethane diisocyanate and toluene
diisocyanate. Examples of suitable aliphatic diisocyanates are straight chain
aliphatic diisocyanates such as 1,6-hexamethylene diisocyanate. Also,
cycloaliphatic diisocyanates can be employed. Examples include isophorone
diisocyanate and 4,4'-methylene-bis-(cyclohexyl isocyanate). Examples of
suitable higher polyisocyanates are 1,2,4-benzene triisocyanate and
polymethylene polyphenyl isocyanate. As with the polyesters, the
polyurethanes can be prepared with unreacted carboxylic acid groups, which
upon neutralization with bases such as amines allows for dispersion into
aqueous medium.
[0068] Terminal and/or pendent carbamate functional groups can be
incorporated into the polyurethane by reacting a polyisocyanate with a polyol
containing the terminal/pendent carbamate groups. Alternatively, carbamate
functional groups can be incorporated into the polyurethane by reacting a
polyisocyanate with a polyol and a hydroxyalkyl carbamate or isocyanic acid
as separate reactants. Carbamate functional groups can also be incorporated
into the polyurethane by reacting a hydroxyl functional polyurethane with a
low molecular weight carbamate functional material via a transcarbamoylation
process similar to the one described above in connection with the
incorporation of carbamate groups into the acrylic polymer. Additionally, an
isocyanate functional polyurethane can be reacted with a hydroxyalkyl
carbamate to yield a carbamate functional polyurethane.
[0069] Other functional groups such as ethylenic unsaturation, amide, thiol,
and urea may be incorporated into the polyurethane as desired using suitably
functional reactants if available, or conversion reactions as necessary to yield
the desired functional groups. Such techniques are known to those skilled in
the art.
[0070] Suitable polycarbonates may be prepared by reacting phosgene or
carbonate diesters with one or more polyols including any of those disclosed
-20-
above in the preparation of the polyester, as known to those skilled in the art.
Bisphenol A is used as the polyol in one embodiment of the present invention.
[0071] Hydroxyl functionality is often terminal to polycarbonates. The
hydroxyl functional groups may be converted to other functional groups as
desired.
[0072] Examples of polyether polyols are polyalkylene ether polyols which
include those having the following structural formula:
O OH
R
m
or
where the substituent RI is hydrogen or lower alkyl containing from 1 to 5
carbon atoms including mixed substituents, and n is typically from 2 to 6 and
m is from 8 to 100 or higher. Included are poly(oxytetramethylene) glycols,
poly(oxytetraethylene) glycols, poly(oxy-1,2-propylene) glycols, and poly(oxy-
1,2-butylene) glycols.
[0073] Also useful are polyether polyols formed from oxyalkylation of various
polyols, for example, diols such as ethylene glycol, 1,6-hexanediol, Bisphenol
A and the like, or other higher polyols such as trimethylolpropane,
pentaerythritol, and the like. Polyols of higher functionality which can be
utilized as indicated can be made, for instance, by oxyalkylation of
compounds such as sucrose or sorbitol. One commonly utilized oxyalkylation
method is reaction of a polyol with an alkylene oxide, for example, propylene
or ethylene oxide, in the presence of an acidic or basic catalyst. Particular
polyethers include those sold under the names TERATHANE and TERACOL,
available from E. I. Du Pont de Nemours and Company, Inc., and POLYMEG,
-21-
available from Q 0 Chemicals, Inc., a subsidiary of Great Lakes Chemical
Corp.
[0074J Pendant carbamate functional groups may be incorporated into the
polyethers by a transcarbamoylation reaction. Other functional groups such as
acid, amine, epoxide, amide, thiol, and urea may be incorporated into the
polyether as desired using suitably functional reactants if available, or
conversion reactions as necessary to yield the desired functional groups.
[0075] Appropriate mixtures of resinous materials may also be used in the
invention. The amount of the resinous material in the curable film-forming
composition generally ranges from 5 to 75 percent by weight based on the
total weight of the curable film-forming composition.
[0076] The curable film-forming composition of b) used to prepare the optical
element of the present invention further comprises ii) a curing (crosslinking)
agent having reactive functional groups that are reactive with functional
groups in the resinous material of i). The curing agent may comprise, for
example, an aminoplast resin, a polyisocyanate, a blocked polyisocyanate, a
polyepoxide, a polyacid, an anhydride, a polyanhydride, a polyamine, a
polyethylenically unsaturated material such as a polyvinyl ether or
poly(meth)acrylate, and/or a polyol.
[0077] Useful aminoplasts can be obtained from the condensation reaction of
formaldehyde with an amine or amide. Nonlimiting examples of amines or
amides include melamine, urea and benzoguanamine.
[0078] Although condensation products obtained from the reaction of alcohols
and formaldehyde with melamine, urea or benzoguanamine are most
common, condensates with other amines or amides can be used. For
example, aldehyde condensates of glycoluril, which yield a high melting
crystalline product useful in powder coatings, can be used. Formaldehyde is
the most commonly used aldehyde, but other aldehydes such as
acetaldehyde, crotonaldehyde, and benzaldehyde can also be used.
[0079] The aminoplast can contain imino and methylol groups. In certain
instances, at least a portion of the methylol groups can be etherified with an
alcohol to modify the cure response. Any monohydric alcohol like methanol,
ethanol, n-butyl alcohol, isobutanol, and hexanol can be employed for this
-22-
purpose. Nonlimiting examples of suitable aminoplast resins are
commercially available from Cytec Industries, Inc. under the trademark
CYMEL® and from Solutia, Inc. under the trademark RESIMENE®.
Particularly useful aminoplasts include CYMEL® 385 (suitable for waterbased
compositions), CYMEL® 1158 imino-functional melamine
formaldehyde condensates, and CYMEL® 303. Another useful crosslinking
agent from Cytec Industries, Inc. that reacts in a manner similar to an
aminoplast resin is Tris(alkoxycarbonylamino) Triazine sold under the
tradename Cylink® 2000.
[0080] Other crosslinking agents suitable for use include polyisocyanate
crosslinking agents. As used herein, the term "polyisocyanate" is intended to
include blocked (or capped) polyisocyanates as well as unblocked
polyisocyanates. The polyisocyanate can be aliphatic, aromatic, or a mixture
thereof. Although higher polyisocyanates such as isocyanurates of
diisocyanates are often used, diisocyanates can also be used. Isocyanate
prepolymers, for example reaction products of polyisocyanates with polyols
also can be used. Mixtures of polyisocyanate crosslinking agents can be
used.
[0081] The polyisocyanate which is utilized as a crosslinking agent can be
prepared from a variety of isocyanate-containing materials. Examples of
suitable polyisocyanates include trimers prepared from the following
diisocyanates: toluene diisocyanate, 4,4'-methylene-bis(cyclohexyl
isocyanate), isophorone diisocyanate, an isomeric mixture of 2,2,4- and
2,4,4-trimethyl hexamethylene diisocyanate, 1,6-hexamethylene diisocyanate,
tetramethyl xylylene diisocyanate and 4,4'-diphenylmethylene diisocyanate.
In addition, blocked polyisocyanate prepolymers of various polyols such as
polyester polyols can also be used.
[0082] Isocyanate groups may be blocked or unblocked as desired. If the
polyisocyanate is to be blocked or capped, any suitable aliphatic,
cycloaliphatic, or aromatic alkyl monoalcohol or phenolic compound known to
those skilled in the art can be used as a capping agent for the polyisocyanate.
Examples of suitable blocking agents include those materials which would
unblock at elevated temperatures such as lower aliphatic alcohols including
-23-
methanol, ethanol, and n-butanol; cycloaliphatic alcohols such as
cyclohexanol; aromatic-alkyi alcohols such as phenyl carbinol and
methylphenyl carbinol; and phenolic compounds such as phenol itself and
substituted phenols wherein the substituents do not affect coating operations,
such as cresol and nitrophenol. Glycol ethers may also be used as capping
agents. Suitable glycol ethers include ethylene glycol butyl ether, diethylene
glycol butyl ether, ethylene glycol methyl ether and propylene glycol methyl
ether. Other suitable capping agents include oximes such as methyl ethyl
ketoxime, acetone oxime and cyclohexanone oxime, lactams such as epsiloncaprolactam,
pyrazoles such as dimethyl pyrazole, and amines such as
diisopropylamine.
[0083] Polyepoxides are suitable curing agents for polymers having carboxylic
acid groups and/or amine groups. Examples of suitable polyepoxides include
low molecular weight polyepoxides such as 3,4-epoxycyclohexylmethyl 3,4-
epoxycyclohexanecarboxylate and bis(3,4-epoxy-6-methylcyclohexyl-methyl)
adipate. Higher molecular weight polyepoxides, including polyglycidyl ethers
of polyhydric phenols and alcohols, are also suitable as crosslinking agents.
[0084] Polyacids, particularly polycarboxylic acids, are good curing agents for
polymers having epoxy functional groups. Examples of suitable
polycarboxylic acids include adipic, succinic, sebacic, azelaic, and
dodecanedioic acid. Other suitable polyacid crosslinking agents include acid
group-containing acrylic polymers prepared from an ethylenically unsaturated
monomer containing at least one carboxylic acid group and at least one
ethylenically unsaturated monomer that is free from carboxylic acid groups.
Such acid functional acrylic polymers can have an acid number ranging from
30 to 150. Acid functional group-containing polyesters can be used as well.
Low molecular weight polyesters and half-acid esters can be used which are
based on the condensation of aliphatic polyols with aliphatic and/or aromatic
polycarboxylic acids or anhydrides. Examples of suitable aliphatic polyols
include ethylene glycol, propylene glycol, butylene glycol, 1,6-hexanediol,
trimethylol propane, di-trimethylol propane, neopentyl glycol, 1,4-
cyclohexanedimethanol, pentaerythritol, and the like. The polycarboxylic
acids and anhydrides may include, inter alia, terephthalic acid, isophthalic
-24-
acid, phthalic acid, phthalic anhydride, tetrahydrophthalic acid,
tetrahydrophthalic anhydride, hexahydrophthalic anhydride,
methylhexahydrophthalic anhydride, chlorendic anhydride, and the like.
Mixtures of acids and/or anhydrides may also be used. The above-described
polyacid crosslinking agents are described in further detail in U.S. Patent No.
4,681,811 at column 6, line 45 to column 9, line 54, which is incorporated
herein by reference.
[0085] Polyethylenically unsaturated curing agents; i. e., materials having
multiple ethylenically unsaturated groups, are particularly useful in filmforming
compositions that cure using actinic radiation; e. g., UV curable
compositions. Polyvinyl ethers, such as those available from Morflex, Inc.,
under the name Vectomer, are examples of suitable curing agents.
Poly(meth)acrylate curing agents include ethylene glycol di(meth)acrylate,
tetraethylene glycol di(meth)acrylate, glycerol di(meth)acrylate, glycerol
tri(meth)acrylate, 1,3-propylene glycol di(meth)acrylate, dipropylene glycol
di(meth)acrylate, 1,4-butanediol di(meth)acrylate, 1,2,4-butanetriol
tri(meth)acrylate, 1,6-hexanediol di(meth)acrylate, 1,4-cyclohexanediol
di(meth)acrylate, 1,4-benzenediol di(meth)acrylate, pentaerythritol
tetra(meth)acrylate, 1,5-pentanediol di(meth)acrylate, trimethylolpropane
di(meth)acrylate and trimethylolpropane tri(meth)acrylate.
[0086] Nonlimiting examples of suitable polyamine crosslinking agents include
primary or secondary diamines or polyamines in which the radicals attached
to the nitrogen atoms can be saturated or unsaturated, aliphatic, alicyclic,
aromatic, aromatic-substituted-aliphatic, aliphatic-substituted-aromatic, and
heterocyclic. Nonlimiting examples of suitable aliphatic and alicyclic diamines
include 1,2-ethylene diamine, 1,2-propylene diamine, 1,8-octane diamine,
isophorone diamine, propane-2,2-cyclohexyl amine, and the like. Nonlimiting
examples of suitable aromatic diamines include phenylene diamines and
toluene diamines, for example o-phenylene diamine and p-tolylene diamine.
Polynuclear aromatic diamines such as 4,4'-biphenyl diamine, methylene
dianiline and monochloromethylene dianiline are also suitable.
[0087] Suitable polyol crosslinking agents include any polyols mentioned
above.
-25-
[0088] Appropriate mixtures of curing agents may also be used in the
invention. The amount of the curing agent in the curable film-forming
composition generally ranges from 5 to 75 percent by weight based on the
total weight of the curable film-forming composition.
[0089] The curable film-forming composition of b) further comprises iii) a
material different from i) and ii), comprising a blocked isocyanate group and
another different functional group capable of reacting with functional groups
on the resinous material of i), functional groups on the curing agent of ii),
functional groups on a superposed coating, and/or functional groups on the
substrate. In one embodiment of the present invention, the isocyanate group
is blocked with a blocking agent capable of deblocking at a temperature as
low as 100°C, particularly useful when the film-forming composition is curable
by actinic radiation. In a separate embodiment, such as when the film-forming
composition is thermally curable, the blocking agent may be capable of
deblocking at or below a temperature at which any of the functional groups, i.
e., functional groups on the material of iii), functional groups on the resinous
material of i), functional groups on the curing agent of ii), functional groups on
a superposed coating, and/or functional groups on the substrate, react w/
each other. Though not intending to be bound by theory, it is intended in any
embodiment that free isocyanate groups on the material of iii) may be
available to react with groups on the resinous material of i), groups on the
curing agent of ii), groups on a superposed coating, and/or groups on the
substrate, regardless of the method of cure. Such free isocyanate groups on
the material of iii) may be available to react during the curing reaction of the
resinous material of i) and the curing agent of ii) by deblocking at or below the
curing temperature of the resinous material of i) and the curing agent of ii),
while not adversely affecting the storage stability of the curable film-forming
composition.
[0090] The blocking agent used in the material of iii) may be any blocking
agent known to be capable of deblocking at a temperature as low as 100°C,
or capable of deblocking at or below a temperature at which any of the
functional groups in the film-forming composition react w/ each other. Such
deblocking may be enabled or enhanced by the use of known catalysts. The
-26-
catalyst may comprise Lewis bases, Lewis acids and/or insertion catalysts
described in Ullmann's Encyclopedia of Industrial Chemistry, 5th Edition,
1992, Volume A21, pp. 673 to 674, which description is herein incorporated
by reference. For example, the catalyst may comprise tin octylate, dibutyltin
diacetate, dibutyltin dilaurate, dibutyltin mercaptide, dibutyltin dimaleate,
dimethyltin diacetate, dimethyltin dilaurate, dimethyltin mercaptide, dimethyltin
dimaleate, triphenyltin acetate, triphenyltin hydroxide, 1,4-
diazabicyclo[2.2.2]octane, and/or triethylamine. Triorganotin materials such
as those disclosed in U. S. Patent 5,902,871, col. 4, line 32 to col. 8, line 7,
and U. S. Patent 5,880,178, col. 4, line 15 to col. 8, line 18, incorporated
herein by reference, may be used. Bismuth catalysts as known in the art may
also be used. Examples of blocking agents that may be used are phenols
(e.g. phenol, nonylphenol, cresol), oximes (e.g. butanone oxime,
cyclohexanone oxime), lactams (e.g. e-caprolactam), secondary amines (e.g.
diisopropyl-amine) and pyrazoles (e.g. dimethylpyrazole), imidazoles,
triazoles). Suitable examples of blocking agents most often used include 3,5-
dimethylpyrazole and N-t-butylbenzyl amine. Mixtures of blocking agents may
also be used.
[0091] As noted above, the material of iii) further comprises at least one other
different functional group capable of reacting with groups on the resinous
material of i), groups on the curing agent of ii), groups on a superposed
coating, and/or groups on the substrate. The functional groups may be any of
those disclosed above in association with the resinous material or the curing
agent. Alternatively, in certain embodiments, the functional group on the
material of iii) comprises (meth)acryloyl, vinyl, ally!, maleinimido, trialkoxysilyl
and/or haloalkyl.
[0092] In particular embodiments, the material of iii) comprises blocked
trialkoxysilylpropyl isocyanates such as triethoxysilylpropyl isocyanate and/or
trimethoxysilylpropyl isocyanate blocked with, most often, 3,5-
dimethylpyrazole.
[0093] In a separate embodiment, the material of iii) may comprise a blocked
isocyanatoalkyl(meth)acrylate such as isocyanatoethyl(meth)acrylate, most
often blocked with 3,5-dimethylpyrazole. lsocyanatoethyl(meth)acrylate
blocked with butanone oxime is also suitable and is available from Showa
Denko K. K. as KarenzMOI-BM.
[0094] The material of iii) is present in the curable film-forming composition at
least in an amount sufficient to improve adhesion between the curable filmforming
composition and the substrate and/or a superposed coating
compared to a similar optical element that does not contain (i. e., is
substantially free of) the material of iii) in the curable film-forming composition.
Adhesion may be measured by a standard method, for example, ASTM D-
3359-93 (Standard Test Method for Measuring Adhesion by Tape Test-
Method B). Typically, the material of iii) is present in the curable film-forming
composition in an amount up to 20 percent by weight, often up to 10 percent
by weight, based on the total weight of resin solids in the curable film-forming
composition.
[0095] As discussed earlier, the optical element of the present invention is
adapted to possess a light influencing property and may further comprise a
material to provide a light influencing property. Such a material may be
inorganic or organic and may be present in the substrate, curable film-forming
composition and/or in a superposed coating or film as described below.
[0096] A wide variety of photochromic materials may be used in the optical
article of the present invention to provide a light influencing property. The
photochromic materials may be provided in a variety of forms. Examples
include: a single photochromic compound; a mixture of photochromic
compounds; a material containing a photochromic compound, such as a
monomeric or polymeric ungelled solution; a material such as a monomer or
polymer to which a photochromic compound is chemically bonded; a material
comprising and/or having chemically bonded to it a photochromic compound,
the outer surface of the material being encapsulated (encapsulation is a form
of coating), for example with a polymeric resin or a protective coating such as
a metal oxide that prevents contact of the photochromic material with external
materials such as oxygen, moisture and/or chemicals that have a negative
effect on the photochromic material; such materials can be formed into a
particulate prior to applying the protective coating as described in U.S.
Patents 4,166,043 and 4,367,170; a photochromic polymer, e.g., a
-28-
photochromic polymer comprising photochromic compounds bonded together;
or, mixtures thereof.
[0097] The inorganic photochromic material may contain crystallites of silver
halide, cadmium halide and/or copper halide. Other inorganic photochromic
materials may be prepared by the addition of europium (II) and/or cerium(lll)
to a mineral glass such as a soda-silica glass. In another embodiment, the
inorganic photochromic materials are added to molten glass and formed into
particles that are incorporated into the curable film-forming composition. Such
inorganic photochromic materials are described in Kirk Othmer Encyclopedia
of Chemical Technology. 4th Edition, Volume 6, pages 322-325.
[0098] The photochromic material may be an organic photochromic material
having an activated absorption maxima in the range from 300 to 1000
nanometers. In one embodiment, the organic photochromic material
comprises a mixture of (a) an organic photochromic material having a visible
lambda max of from 400 to less than 550 nanometers, and (b) an organic
photochromic material having a visible lambda max of from 550 to 700
nanometers.
[0099] The photochromic material may alternatively comprise an organic
photochromic material that may be chosen from pyrans, oxazines, fulgides,
fulgimides, diarylethenes and mixtures thereof.
[00100] Non-limiting examples of photochromic pyrans that may be used
herein include benzopyrans, and naphthopyrans, e.g., naphtho[1,2-b]pyrans,
naphtho[2,1-b]pyrans, indeno-fused naphthopyrans and heterocyclic-fused
naphthopyrans, spiro-9-fluoreno[1,2-b]pyrans, phenanthropyrans,
quinolinopyrans; fluoroanthenopyrans and spiropyrans, e.g.,
spiro(benzindoline)naphthopyrans, spiro(indoline)benzopyrans,
spiro(indoline)naphthopyrans, spiro(indoline)quinolinopyransand
spiro(indoline)pyrans and mixtures thereof. Non-limiting examples of
benzopyrans and naphthopyrans are disclosed in U.S. Patent 5,645,767 at
column 2, line 16 to column 12, line 57; U.S. Patent 5,723,072 at column 2,
line 27 to column 15, line 55; U.S. Patent 5,698,141 at column 2, line 11 to
column 19, line 45; U.S. Patent 6,022,497 at column 2, line 21 to column 11,
line 46; U.S. Patent 6,080,338 at column 2, line 21 to column 14, line 43; U.S.
-29-
Patent 6,136,968 at column 2, line 43 to column 20, line 67; U.S. Patent
6,153,126 at column 2, line 26 to column 8, line 60; U.S. Patent 6,296,785 at
column 2, line 47 to column 31, line 5; U.S. Patent 6,348,604 at column 3, line
26 to column 17, line 15; U.S. Patent 6,353,102 at column 1, line 62 to column
11, line 64; U.S. Patent 6,630,597 at column 2, line 16 to column 16, line 23;
and U.S. Patent 6,736,998 at column 2, line 53 to column 19, line 7 which
disclosures are incorporated herein by reference. Further non-limiting
examples of naphthopyrans and complementary organic photochromic
substances are described in U.S. Patent 5,658,501 at column 1, line 64 to
column 13, line 17, which disclosure is incorporated herein by reference.
Spiro(indoline)pyrans are also described in the text, Techniques in Chemistry.
Volume III, "Photochromism", Chapter 3, Glenn H. Brown, Editor, John Wiley
and Sons, Inc., New York, 1971.
[00101] Examples of photochromic oxazines that may be used include
benzoxazines, naphthoxazines, and spiro-oxazines, e.g.,
spiro(indoiine)naphthoxazines, spiro(indoline)pyridobenzoxazines,
spiro(benzindoline)pyridobenzoxazines, spiro(benzindoline)naphthoxazines,
spiro(indoline)benzoxazines, spiro(indoline)fluoranthenoxazine,
spiro(indoline)quinoxazine and mixtures thereof.
[00102] Examples of photochromic fulgides orfulgimides that may be used
include: fulgides and fulgimides, which are disclosed in U.S. Patents
4,685,783 at column 1, line 57 to column 5, line 27, and in U.S. Patent
4,931,220 at column 1, line 39 through column 22, line 41, the disclosure of
such fulgides and fulgimides are incorporated herein by reference. Nonlimiting
examples of diarylethenes are disclosed in U.S. Patent Application
2003/0174560 paragraphs [0025] to [0086].
[00103] Polymerizable organic photochromic materials, such as polymerizable
naphthoxazines disclosed in U.S. Patent 5,166,345 at column 3, line 36 to
column 14, line 3; polymerizable spirobenzopyrans disclosed in U.S. Patent
5,236,958 at column 1, line 45 to column 6, line 65; polymerizable
spirobenzopyrans and spirobenzothiopyrans disclosed in U.S. Patent
5,252,742 at column 1, line 45 to column 6, line 65; polymerizable fulgides
disclosed in U.S. Patent 5,359,085 at column 5, line 25 to column 19, line 55;
-30-
polymerizable naphthacenediones disclosed in U.S. Patent 5,488,119 at
column 1, line 29 to column 7, line 65; polymerizable spirooxazines disclosed
in U.S. Patent 5,821,287 at column 3, line 5 to column 11, line 39;
polymerizable polyalkoxylated naphthopyrans disclosed in U.S. Patent
6,113,814 at column 2, line 23 to column 23, line 29; and the polymeric matrix
compatibilized naphthopyran of U.S. Patent 6,555,028 at column 2, line 40 to
column 24, line 56 may be used. The disclosures of the aforementioned
patents on polymerizable organic photochromic materials are incorporated
herein by reference.
[00104] The photochromic materials can be incorporated, for example, into
the curable film-forming composition by various means. The photochromic
materials may be incorporated, e.g., dissolved and/or dispersed, into the
composition, or polymerized with other components of the composition.
Alternatively, the photochromic materials may be incorporated into the
composition by imbibition, permeation or other transfer methods as known by
those skilled in the art.
[00105] Typically the photochromic material is present in the optical element
in a photochromic amount; that is, in an amount yielding a color change
distinguishable by the naked eye upon exposure to radiation. In one
embodiment, the amount of photochromic material incorporated into the
curable film-forming composition may range from 0.5 to 40 weight percent
based on the weight of the solids in the curable film-forming composition. In
alternate embodiments, the amount of photochromic material ranges from 1 to
30 weight percent, from 3 to 20 weight percent, or from 3 to 10 weight
percent. The amount of photochromic material in the curable film-forming
composition may range between any combination of these values, inclusive of
the recited range.
[00106] Adjuvant materials may also be incorporated into the curable filmforming
composition. Such adjuvants may be incorporated prior to,
simultaneously with or subsequent to application or incorporation of any
photochromic material. For example, ultraviolet light absorbers may be
admixed with photochromic materials before their addition to the composition
or such absorbers may be superposed, e.g., superimposed, as a coating or
-31-
film between the curable film-forming composition and the incident light.
However, caution should be exercised that the ultraviolet light absorbers are
not used in such amounts as to interfere with the performance of the
photochromic material, if present.
[00107] In addition to ultraviolet light stabilizers, other adjuvants such as
stabilizers may be used to improve the light fatigue resistance of
photochromic materials. Non-limiting examples of stabilizers include hindered
amine light stabilizers (HALS), asymmetric diaryloxalamide (oxanilides)
compounds and singlet oxygen quenchers, e.g., a nickel ion complex with an
organic ligand, polyphenolic antioxidants and mixtures of such stabilizers are
contemplated. The adjuvants may be used in the photochromic adhesive
individually or as a mixture, e.g., of stabilizers in combination with ultraviolet
light absorbers, as known to those skilled in the art.
[00108] Further adjuvant materials can be incorporated into the curable filmforming
composition used in the optical element of the present invention, e.g.,
conventional ingredients that aid in processing or impart desired
characteristics to the resulting optical elements. Non-limiting examples of
such ingredients include solvents, e.g., aqueous and/or organic solvents,
rheology control agents, surfactants, initiators, catalysts, cure-inhibiting
agents, reducing agents, acids, bases, preservatives, free radical donors, free
radical scavengers and thermal stabilizers, which adjuvant materials are
known to those skilled in the art.
[00109] The optical element of the present invention may further comprise c)
an at least partial film or coating superposed on the curable film-forming
composition of b) and different therefrom. Such a coating or film may
comprise, inter alia, a photochromic coating, tint coating, polarizing coating,
and/or an abrasion resistant or other protective coating. Any of the coatings
discussed earlier as applied directly to the substrate may additionally or
alternatively be used as the superposed coating c). Likewise, any coatings
discussed here below as the superposed coating c) may additionally or
alternatively be applied directly to the substrate.
[00110] The types of material used for the film or coating may vary widely and
be chosen from the polymeric organic materials of the substrate and the
-32-
protective films described hereinafter. The thickness of the films of polymeric
organic materials may vary widely. The thickness may range, for example,
from 0.1 mil to 40 mils and any range of thicknesses between these values,
inclusive of the recited values. However, if desired, greater thicknesses may
be used.
[00111] The polymeric organic materials may be chosen from thermosetting
materials, thermoplastic materials and mixtures thereof. Such materials
include the polymeric organic materials chosen for the substrate as well as
protective films. Other examples of films of polymeric organic materials are
disclosed in U.S. Patent Publication 2004/0096666 in paragraphs [0082] to
[0098] which disclosure of such polymeric films is incorporated herein by
reference.
[00112] In certain embodiments, the film or coating c) comprises
thermoplastic polymeric organic materials chosen from nylon, poly(vinyl
acetate), vinyl chloride-vinyl acetate copolymer, poly (Ci-Cg alkyl) acrylates,
poly (CrC8 alkyl) methacrylates, styrene-butadiene copolymer resin,
poly(urea-urethanes), polyurethanes, polyterephthalates, polycarbonates,
polycarbonate-silicone copolymer and mixtures thereof.
[00113] Optionally, compatible (chemically and color-wise) fixed tint dyes may
be added or applied to the substrate, curable film-forming composition, and/or
superposed films to achieve a more aesthetic result, for medical reasons, or
for reasons of fashion. For example, the dye may be selected to complement
the color resulting from activated photochromic materials, e.g., to achieve a
more neutral color or absorb a particular wavelength of incident light. In
another embodiment, the dye may be selected to provide a desired hue to the
host material when the photochromic materials are in an unactivated state.
[00114] In a further embodiment, the aforementioned fixed tint dyes may be
associated with the protective films described hereinafter used with the optical
elements of the present invention as known to those skilled in the art. See for
example, U.S. Patent 6,042,737 at column 4, line 43 to column 5, line 8,
which disclosure related to tinting coated substrates is incorporated herein by
reference.
-33-
[00115] Often, a protective film is typically applied to the substrate to prevent
scratches from the effects of friction and abrasion. The protective film may
also serve as the superposed film or coating c). The protective film connected
to the optical element of the present invention, in a particular embodiment, is
an at least partially abrasion resistant film. The phrase "an at least partially
abrasion resistant film" refers to an at least partial film of an at least partially
cured coating or sheet of a protective polymeric material that demonstrates a
resistance to abrasion that is greater than the standard reference material,
typically a plastic made of CR-39® monomer available from PPG Industries,
Inc, as tested in a method comparable to ASTM F-735 Standard Test Method
for Abrasion Resistance of Transparent Plastics and Coatings Using the
Oscillating Sand Method.
[00116] The protective film may be chosen from protective sheet materials,
protective gradient films (which also provide a gradient in hardness for the
films between which they are interposed), protective coatings and
combinations thereof. Protective coatings such as hardcoats may be applied
onto the surface of the polymeric film, the substrate and/or any applied films,
e.g., superjacent to protective transitional films.
[00117] When the protective film is chosen from protective sheet materials, it
may be chosen from the protective polymeric sheet materials disclosed in
paragraphs [0118] to [0126] of U.S. Patent Publication 2004/0096666.
[00118] The protective gradient films provide an at least partially abrasion
resistant film and may be subsequently coated with another protective film.
The protective gradient film may serve to protect the article during shipping or
subsequent handling prior to the application of the additional protective film.
After application of an additional protective film, the protective gradient film
provides a gradient in hardness from one applied film to another. The
hardness of such films may be determined by methods known to those skilled
in the art. In another non-limiting embodiment, a protective film is superjacent
to a protective gradient film. Non-limiting examples of protective films
providing such gradient properties include the radiation cured (meth)acrylatebased
coatings described in U.S. Patent Application Publication
-34-
2003/0165686 in paragraphs [0010] to [0023] and [0079] to [0173],
incorporated herein by reference.
[00119] The protective films may also include protective coatings. Examples
of protective coatings known in the art that provide abrasion and scratch
resistance are chosen from polyfunctional acrylic hard coatings, melaminebased
hard coatings, urethane-based hard coatings, alkyd-based coatings
and organosilane type coatings. Non-limiting examples of such abrasion
resistant coatings are disclosed in U.S. Patent Application 2004/0096666 in
paragraphs [0128] to [0149], and in U.S. Patent Application 2004/0207809 in
paragraphs [0205] to [0249], both disclosures incorporated herein by
reference.
[00120] In one embodiment, the optical element of the present invention
further comprises an at least partially polarizing surface treatment, coating, or
film. The phrase "at least partially polarizing" means that from some to all of
the vibrations of the electric field vector of lightwaves is confined to one
direction or plane by the surface treatment. Such polarizing effects may be
achieved by applying to the optical element a film having an aligned dichroic
material to at least partially polarize transmitted radiation. In one non-limiting
embodiment, a polymeric sheet is stretched to align the dichroic material
applied to the polymeric sheet. In another non-limiting embodiment, a coating
is cured in a directional fashion, e.g., using polarized ultraviolet radiation, to
align the dichroic materials in the coating.
[00121] In another embodiment, the optical element further comprises an at
least partially antireflective surface treatment. The phrase "an at least
partially antireflective surface" treatment means that there is an at least partial
improvement in the antireflective nature of the optical element to which it is
applied. In non-limiting embodiments, there may be a reduction in the amount
of glare reflected by the surface of the treated optical element and/or an
increase in the percent transmittance through the treated optical element as
compared to an untreated optical element.
[00122] In another non-limiting embodiment, an at least partially antireflective
surface treatment, e.g., a monolayer or multilayer of metal oxides, metal
fluorides, or other such materials, can be connected to the polymeric film
-35-
surface of the optical elements, e.g., lenses, of the present invention through
vacuum evaporation, sputtering, or some other method.
[00123] The optical element of the present invention may further comprise an
at least partially hydrophobic surface treatment. The phrase "an at least
partially hydrophobic surface" is a film that at least partially improves the
water repellent nature of the substrate to which it is applied by reducing the
amount of water from the surface that can adhere to the substrate as
compared to an untreated substrate.
[00124] The optical elements of the present invention may be produced by a
variety of methods. The optical element of the present invention may be
prepared by applying the curable film-forming composition to the substrate, for
example, using any of the methods used in coating technology. Non-limiting
examples include spray coating, spin coating, spin and spray coating, spread
coating, curtain coating, dip coating, casting-coating, roll-coating, reverse roll
coating, transfer roll coating, kiss/squeeze coating, gravure roll coating, blade
coating, knife coating, and rod/bar coating.
[00125] In one embodiment, when the optical element of the present
invention further comprises a film or coating c) superposed on the curable
film-forming composition of b), or when the optical element further comprises
protective and/or other films, the curable film-forming composition of b) may
be applied directly to the substrate, or may first be applied to the other film c)
and the combination of the film-forming composition of b) and the additional
film c) may be applied as a composite to the substrate, such as by lamination.
[00126] The optical elements of the present invention may alternatively be
prepared by utilizing a mold of a chosen design as the front mold, the curable
film-forming composition of b), and a preformed optical substrate i), e.g., a
preformed lens substrate, having a generally convex front surface, a generally
concave back surface and a predetermined lens correction (if any) at its
optical center, as a back mold. The method of forming lenses as disclosed in
U.S. Patent 4,873,029 may also be used to form the optical elements of the
present invention.
[00127] Following application of the curable film-forming composition to the
surface of the substrate, any solvent used to prepare the curable film-forming
-36-
composition may be evaporated. This may occur before, during and/or after
applying any subsequent coatings. The curable film-forming composition may
also be at least partially cured before, during and/or after applying any
superposed films or coatings. This may be accomplished, for example, by
exposing a UV-curable composition to ultraviolet radiation before, during
and/or after the process of connecting the at least partial film to it.
[00128] Methods used for curing the curable film-forming composition include
solvent evaporation, radical polymerization, thermal curing,
photopolymerization or a combination thereof. Additional methods include
irradiating the polymerizable material with infrared, ultraviolet, gamma or
electron radiation so as to initiate the polymerization reaction of any
polymerizable components, or to initiate crosslinking mechanisms. This may
be followed by a heating step. If the temperature of the curing method does
not at least achieve 100°C, a separate heating step to at least 100°C may be
performed to allow for deblocking of the isocyanate material of iii).
[00129] The present invention is more particularly described in the following
examples that are intended as illustration only, since numerous modifications
and variations therein will be apparent to those skilled in the art.
Examples
[00130] Examples 1 and 3 demonstrate preparation of adhesion promoters to
be used in optical elements of the present invention. In Example 1, a
triethoxysilylpropyl isocyanate blocked with 3,5-dimethylpyrazole (DMP) is
prepared. Example 2 is a comparative example, illustrating the preparation of
triethoxysilylpropyl isocyanate blocked with Nethylaminoisobutyltrimethoxysilane.
Example 3 illustrates the preparation of
3,5-dimethylpyrazole-blocked trimethoxysilylpropyl isocyanate.
Example 1
[00131] Triethoxysilylpropyl isocyanate (25 g, 0.1 moles) was weighed into
100 ml round bottom jacketed round bottom flask equipped with a refrigerated
circulator, thermometer and magnetic stirrer. Ethyl acetate (25 grams) was
weighed into the flask. 3,5-dimethylpyrazole (9.4 grams, 0.1 moles) was
added to the stirring mixture in 5 separate additions. After each addition the
-37-
temperature increased. The next addition was made once the temperature
decreased to final addition. The ethyl acetate was removed on a rotary evaporator to
provide a clear viscous liquid. The absence of free isocyanate was confirmed
by infrared spectroscopy. The blocked isocyanate chemical structure was
confirmed by proton NMR.
Example 2 (Comparative)
[00132] The same procedure as in Example 1 was followed except that the
liquid N-ethylaminoisobutyltrimethoxysilane (21.3g) was added dropwise to
the stirring at a rate such that the temperature remained at 28°C. Once the
addition was complete the temperature was raised to 50°C for 20 minutes
then cooled to room temperature. The ethyl acetate was removed on a rotary
evaporator to provide a clear viscous liquid that yellowed over time. The
absence of free isocyanate was confirmed by infrared spectroscopy. The
blocked isocyanate chemical structure was confirmed by proton NMR. The
ratio of ethoxy protons to methoxy protons indicated some hydrolysis
occurred.
Example 3
[00133] The same procedure as in Example 1 was used except that instead of
stirring for 24 hours after the final DMP addition, the mixture was heated to
50°C for 30 minutes. The ethyl acetate was removed on a rotary evaporator
to provide a clear viscous liquid. The absence of free isocyanate was
confirmed by infrared spectroscopy. The blocked isocyanate chemical
structure was confirmed by proton NMR.
Example 4
[00134] In the following example, piano PDQ coated polycarbonate lenses
obtained from Gentex Optics were used. The test lenses were treated with an
oxygen plasma for 1 minute using a Plasmatech machine at a power setting
of 100 Watts while introducing oxygen at a rate of 100 ml/min into the vacuum
chamber of the Plasmatech machine. The lenses were then rinsed with
-38-
deionized water and dried with air. A photochromic polyurethane coating
composition was applied to the plasma treated lenses by spin coating and
thermally cured. The components of the polyurethane composition and their
amounts are tabulated in Table 1. The components of the polyurethane
composition were mixed for 30 minutes at 60 °C, followed by 30 minutes of
mixing at ambient temperature prior to being applied to the lenses. The
photochromic polyurethane coating was approximately 20 microns thick.
TABLE 1
Formulation
Component Amount. Grams
DesmodurPL3175A(a) 2.6
VestanatB 1358A(b) 7.6
PC 1122 (c) 8.0
HCS 6234 polyol (d) 1.9
Tinuvin 144 UV stabilizer (e) 0.36
A-187(f) 0.53
N-methyl pyrrolidinone 5.6
Photochromic Material (g) 0.58
L-5340 surfactant (h) 0.05
Dibutvltin dilaurate 0.16
(a) Methyl ethyl ketoxime blocked hexamethylene diisocyanate (Bayer)
(b) Methyl ethyl ketoxime blocked isophorone diisocyanate trimer (CreaNova,
Inc.)
(c) Polyhexane carbonate diol (Stahl)
(d) Polyacrylate polyol (Composition D in Example 1 of US 6,187,444 B1)
(e) Hindered amine light stabilizer (Ciba-Geigy)
(f) Y Glycidoxypropyl trimethoxysilane coupling agent (OSi)
(g) A mixture of naphthopyran photochromic materials in proportions designed
to give a gray tint to the coating when activated by UV radiation.
(h) Surfactant (Niax)
[00135] Nine coating preparations (Examples 4A through 4G) were prepared
using 10 grams each of the dendritic polyester acrylate PRO-6021 and ,025g
-39-
(0.25pph acrylate) of BAPO photoinitiator [bis(2,4,6-trimethylbenzoyl) phenyl
phosphine oxide]. PRO-6021 dendritic polyester acrylate is reported by its
supplier to be a 50/50 blend of neopentylglycol-2-propoxylated diacrylate and
a dendritic polyester acrylate in which approximately 13 of the 16 terminal
hydroxy groups have been acrylated. The materials shown in Table 1 were
added to eight of the nine coating preparations at 2.5pph acrylate and/or
5.0pph acrylate levels.
EXAMPLE
4A (Control)
4B (Comparative)
4C
4D (Comparative)
4E
4F (Comparative)
4G
ADHESION PROMOTER
None; control
N-methylaminopropyltrimethoxysilane
Aliphatic polyisocyanates based on IPDI
(isophorone diisocyanate) (Desmodur PL-340,
available from Bayer Corp) blocked with 3,5-
dimethylpyrazole
glycidoxypropyl trimethoxysilane
Blocked 3-triethoxysilylpropyl isocyanate of
Example 1
Blocked 3-triethoxysilylpropyl isocyanate of
Example 2
Blocked 3-trimethoxysilylpropyl isocyanate of
Example 3
[00136] The photochromic polyurethane coating on the test lenses were
treated by plasma discharge using the Plasmatech machine using the same
conditions used to treat the uncoated piano lenses. The dendritic polyester
acrylate coating preparations were applied to the test lenses by spin coating
to give a wet film weight of approximately 0.06 grams (approximately 10
microns thickness). The coatings were cured in a nitrogen atmosphere with
UV light from a D bulb. Half of the lenses were tested for AB coating
adhesion to the hardcoated polycarbonate lenses using the Crosshatch peel
test.
[00137] The other half of the test lenses there were treated with an oxygen
plasma for 1 minute using a Plasmatech machine at a power setting of 100
Watts while introducing oxygen at a rate of 100 ml/min into the vacuum
chamber of the Plasmatech machine. A non-tintable abrasion resistant
-40-
coating composition, Table 2, was applied onto the lenses and the samples
cured for 3 hours at 100°C in a convection oven.
Table 2: Abrasion resistant coating composition
glycidoxypropyl trimethoxysilane
methyltrimethoxysilane
Deionized water
Nitric acid (70% in water)
Dowanol PM (Propylene glycol methyl
ether, available from Dow Chemical Co.)
Dowanol PM acetate
tetramethylammonium hydroxide, 25% in
methanol
Polydimethylsiloxane surfactant (BYK
306, available from BYK-Chemie USA)
32.4 grams
345.5 grams
291.5 grams
11 4 grams
114 grams
3.3 grams to pH 5.5
0.9 grams
[00138] The hard coated lenses were tested for adhesion of the hard coat
using the Crosshatch peel test. All the adhesion results are shown in Table 3.
Table 3: Crosshatch peel adhesion test results
Example
4A-AB
4A-HC
4B-AB
4B-HC
4B-AB
4B-HC
4B-AB
4B-HC
4C-AB
4C-HC
4C-AB
4C-HC
4D-AB
4D-HC
4D-AB
4D-HC
4E-AB
4E-HC
4E-AB
4E-HC
4F-AB
4F-HC
4F-AB
4F-HC
4G-AB
4G-HC
4G-AB
4G-HC
pph
additive
00
2.5
2.5
5
5
10
10
5
5
10
10
2.5
2.5
5
5
2.5
2.5
5
5
2.5
2.5
5
5
2.5
2.5
5
5
Adhesion Loss
Dry
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
Wet
30%-40%
30%
0%
50%
0%
100%
0%
100%
0%
5-15%
0%
20-30%
5%
0%
0%
0%
0%
0%
0%
0%
10-15%
15-20%
5%
0%
0%
0%
0%
0%
-41-
EXAMPLE 5A
Hvdrophilic Urethane Prepolvmer
[00139] The following materials were added in the order described to a fourneck
round bottom flask equipped with an electronic temperature probe,
mechanical stirrer, condenser, and a heating mantle.
Charge A
Material
N-methyl pyrrolidinone (NMP)
dimethylolpropionic acid (DMPA)
triphenyl phosphite
dibutyltin dilaurate
butylated hydroxytoluene
Weight in qrams
138.9
134.1
1.1
1.1
1.1
Charge B
Material
2-(dicaprolactone)ethyl acrylate
Weight in grams
344.4
Charge C
Material
methylene bis(4-cyclohexylisocyanate)
Weight in grams
524.0
Charge D
Material
diethanolamine
propylene glycol monobutyl ether
Weight in grams
105.1
138.9
[00140] Charge A was stirred in the flask at a temperature of 100°C until all
solids were dissolved. Charge B was added and the mixture was reheated to
80°C. Charge C was added over a 15 minute period and the resulting mixture
was held at 80°C for 3 hours. Charge D was added and the mixture was
cooled to room temperature. The final product was an extremely viscous
-42-
clear yellow solution with an acid value of 38.9 and a percent solids of 82%.
The acid value was measured by potentiometric titration with KOH. The
percent solids was determined by adding a known amount of the material to
an aluminum pan, adding additional water to dilute the material and more
evenly distribute it over the pan. The pan was placed in an oven at 110 °C for
1 hour. The pan was then re-weighed and the percent solids were
determined from the remaining mass (minus the pan) divided by the initial
mass (minus the pan).
EXAMPLE 5B
Photochrornic Hvdrophobic Urethane Prepolvmer
[00141] The following materials were added in the order described to a fourneck
round bottom flask equipped with an electronic temperature probe,
mechanical stirrer, condenser, and a heating mantle.
Charge A
Material
N-methyl pyrrolidinone
Photochrornic A(1;
2-(dicaprolactone)ethyl acrylate
dibutyltin dilaurate
butylated hydroxytoluene
Weiqht in grams
72.1
67.3
103.4
0.3
0.3
Charge B
Material
2-heptyl-3,4-bis(9-isocyanatononyl)-1-
pentyl-cyclohexane(2)
Weight in grams
117.4
(1) Photochrornic A is 3,3-di(4-methoxyphenyl)-6,11,13-trimethyl-13-(2-(2-
(2-hydroxyethoxy)ethoxy)ethoxy)-3H, 13H-indeno[2,1 -f]naphtho[1,2-b]pyran.
(2) Diisocyanate available from Cognis Corporation.
-43-
[00142] Charge A was stirred in the flask and heated to a temperature of
90°C. Charge B was added over a 17 minute period and the mixture was held
at 90°C for 90 minutes and then cooled to room temperature. The final
product was a dark purple liquid with a Brookfield viscosity of 1390 cps
(spindle # 3, 50 rpm, 25°C).
EXAMPLE 5C
Aaueous Dispersion of Photochromic Microparticles Formed From Examples 5A and
SB
[00143] The following materials were added in the order described as follows.
Charge A
Material
water
dimethylethanolamine
propylene glycol monobutyl ether
IGEPAL® CO-897(7) surfactant
EXAMPLE 5A
Weiaht in arams
282.0
5.76
15.84
3.57
90.0
Charge B
Material
2-(dicaprolactone)ethyl acrylate
EXAMPLE 5B
dodecylbenzenesulfonic acid (70% in
isopropanol)
dimethylethanolamine
Weiaht in grams
9.6
49.7
2.33
0.65
Charge C
Material
water
ferrous ammonium sulfate
t-butyl hydroperoxide
Weight in grams
2.0
0.01
0.16
-44-
Charge D
Material
water
sodium metabisulfite
Weight in grams
6.0
0.2
Charge E
Material
dimethylethanolamine
water
Weight in grams
0.24
0.48
(7) A non-ionic surfactant available from Rhodia.
[00144] A pre-emulsion was prepared by stirring Charge A in a glass beaker.
Of the pre-emulsion, 132.37 g was recycled for 15 minutes through a
Microfluidizer® M110T at 8000 psi and 28°C while Charge B was added in
order. The Microfluidizer® M110T is available from the Microfluidics™ division
of MFIC Corporation, Newton, MA. The resulting microemulsion was
transferred to a fourneck round bottom flask equipped with an overhead
stirrer, condenser, electronic temperature probe, and a nitrogen inlet. Charge
C was added rapidly as a mixture and then Charge D was added as a mixture
over a period of 30 minutes. The temperature rose from 30°C to 33°C as
Charge D was added. Finally, Charge E was added to produce a milky purple
dispersion with a pH of 8. The dispersion was 31% solids.
Example 6
Coating Compositions of Agueous Dispersions of Photochromic Microparticles
of Example 5C to evaluate different alkoxv silane additives for adhesion and
shelf-life
[00145] The base hydrosol formulation (A) was prepared as follows:
11 Og of hydrosol particle [03-209-016] of Part I was combined with 36.25 g of
Cymel 328 (available from Cytec Industries), 10.5 g of Kflex 320 and 12.3g of
4.36% solution of Tinuvin-144 in NMP. All were added with stirring. The
solution was stirred overnight prior to adding the adhesion promoters.
-45-
[00146] The following adhesion promoters (Examples 6-1 to 6-8) were
combined with 14.8 grams of (A). Examples 6-5 and 6-6 were used in
accordance with the present invention. All others were comparative.
6-1. 54 g A-187, glycidoxypropyltrimethoxysilane from OSI Specialty
Chemicals.
6-2. 50 g Gelest SIG5839.0 (3-
GLYCIDOXYPROPYL)TRIETHOXYSILANE
6-3. 1.03g SIB1140.0 (Gelest) BIS(2-HYDROXYETHYL)-3-
AMINOPROPYLTRIETHOXYSILANE, 62% in methanol
6-4. 0.65 g SIH6172.0 (Gelest) N-(HYDROXYETHYL)-NMETHYLAMINOPROPYLTRIMETHOXYSILANE
75% in methanol
6-5. 0.68 g DMP blocked isocyanatopropyltrimethoxysilane (Example
3)
6-6. 0.79 g DMP blocked isocyanatopropyltriethoxysilane (Example
1)
6-7. No adhesion promoter, but Cymel 328 was replaced with Cymel
385 in (A)
6-8. 0.54 g A-187, glycidoxypropyltrimethoxysilane from OSI
Specialty Chemicals with Cymel 385.
[00147] PDQ coated Gentex polycarbonate piano lenses were corona treated
for 4 seconds while spinning ~ 1 inch from the corona discharge. The spin
speed was about 200 RPM.
[00148] The coating solutions were applied to the corona treated lenses for 3-
5 seconds at 1200 RPM to achieve wet film weights of 0.18 to 0.22g. 4
lenses for each solution were coated.
[00149] The cure cycle was 80°C for 20-25 min., 120°C for 1 hour. 1/2 of
each coating type was allowed 3 additional hours post cure at 100°C.
[00150] The adhesion test was as follows: A dry cross-hatch with 2 tape pulls
(Scotch tape, 600) was performed prior to any further lens treatment and the
primary adhesion was recorded. The lenses were then boiled in de-ionized
water for 30 minutes. After cooling to room temperature, the cross-hatch and
tape pull test was repeated, recording the results. No loss of primary
adhesion was observed in any of the samples in the initial (dry) test. The data
-46-
in the table only shows the secondary adhesion loss results. Table 4 below
shows the results with the blocked isocyanate adhesion promoters relative to
other silane coupling agents.
Table 4
Example
6-1
6-1
6-1
6-1
6-2
6-2
6-2
6-2
6-3
6-3
6-3
6-3
6-4
6-4
6-4
6-4
6-5
6-5
6-5
6-5
6-6
6-6
6-6
6-6
6-7
6-7
6-7
Cure Cycle
120-1hr
120-1hr
120-1hr+100
3hr
120-1hr+100
3hr
120-1hr
120-1hr
120-1hr+100
3hr
120-1hr+100
3hr
120-1hr
120-1hr
120-1hr+100
3hr
120-1hr+100
3hr
120-1hr
120-1hr
120-1hr+100
3hr
120-1hr+100
3hr
120-1hr
120-1hr
120-1hr+100
3hr
120-1hr+100
3hr
120-1hr
120-1hr
120-1hr+100
3hr
120-1hr+100
3hr
120-1hr
120-1hr
120-1hr+100
Lens
#
L1
12
L1
L2
L1
L2
L1
L2
L1
L2
L1
L2
L1
12
L1
L2
L1
L2
L1
12
L1
L2
L1
L2
L1
L2
L1
Adhesion
%Loss
000
0
20
25
95
85
20
30
99
60
95
60
5
5
0
0
0
0
40
30
80
90
100
100
100
-47-
6-7
6-8
6-8
6-8
6-8
3hr
120-1hr+100
3hr
120-1hr
120-1hr
120-1hr+100
3hr
120-1hr+100
3hr
L2
L1
L2
L1
L2
100
0
0
0
0
Shelf-Life Tests
[00151] The coating solutions above were monitored over time to determine
the shelf-life of these solutions. Only the solutions containing silane coupling
agents that provided 0% adhesion loss (Examples 6-1, 6-5, and 6-8) were
monitored. Examples 6-1 and 6-8 typically gelled in 2-3 days. Example 6-5
did not exhibit unacceptable viscosity increase until 2 - 3 weeks.
[00152] Whereas particular embodiments of this invention have been
described above for purposes of illustration, it will be evident to those skilled
in the art that numerous variations of the details of the present invention may
be made without departing from the invention as defined in the appended
claims.




We claim:
1. An optical element adapted to possess a light influencing property, comprising:
a) a substrate; and
b) a curable film-forming composition applied to at least a portion of the substrate to form a coating thereon, wherein the curable film-forming composition comprises:
i) a resinous material comprising a monomer, oligomer, and/or polymer containing reactive functional groups;
ii) a curing agent having two or more reactive functional groups that are reactive with functional groups in the resinous material of i); and
iii) a material different from i) and ii), comprising a blocked isocyanate group and another different functional group capable of reacting with functional groups on the resinous material of i), functional groups on the curing agent of ii), functional groups on a superposed coating, and/or functional groups on the substrate, wherein the different functional group on the material of iii) comprises trialkoxysilyl, and wherein the isocyanate group is blocked with a blocking agent capable of deblocking at or below a temperature at which any of the functional groups on the material of iii), functional groups on the resinous material of i), functional groups on the curing agent of ii), functional groups on a superposed coating, and/or functional groups on the substrate react with each other, said blocking agent comprising 3,5-dimethylpyrazole and/or N-t-butylbenzyl amine, and wherein the material of iii) is present in the curable film-forming composition at least in an amount sufficient to improve adhesion between the curable film-forming composition and the substrate and/or a superposed coating compared to a substantially identical optical element that does not comprise the material of iii) in the curable film-forming composition.
2. The optical element as claimed in claim 1, wherein the deblocking temperature of the blocking agent is as low as 100° C.
3. The optical element as claimed in claim 1 or 2, wherein the material of iii) is present in the curable film-forming composition in an amount up to 20 percent by weight, based on the total weight of resin solids in the curable film-forming composition.

4. The optical element as claimed in claim 3, wherein the material of iii) is present in the curable
film-forming composition in an amount up to 10 percent by weight, based on the total weight of
resin solids in the curable film-forming composition.
5. The optical element as claimed in claim 1 or 2, comprising a photochromic material comprising an inorganic photochromic material and/or an organic photochromic material.
6. The optical element as claimed in claim 5, wherein the photochromic material is an organic photochromic material comprising pyrans, oxazines, fulgides, fulgimides, and/or diarylethenes.
7. The optical element as claimed in claim 5, wherein the photochromic material is present in the curable film-forming composition.
8. The optical element as claimed in claim 1 or 2, wherein the substrate comprises mineral glass, ceramic material and/or polymeric organic material and is an ophthalmic article.
9. The optical element as claimed in claim 8, comprising an at least partially antireflective surface treatment, an at least partially hydrophobic surface treatment or sequential surface treatments of antireflective and hydrophobic surface treatments directly applied on top of at least a portion of the substrate.

10. The optical element as claimed in claim 1 or 2, comprising c) a film or coating superposed on the curable film-forming composition of b) and different therefrom.
11. The optical element as claimed in claim 10, wherein the superposed coating is an abrasion resistant coating.
12. The optical element as claimed in claim 1 or 2, comprising protective films, at least partially polarizing surface treatments, coatings, or films, and/or combinations thereof, directly applied to at least a portion of the substrate.
13. The optical element as claimed in claim 1 or 2, wherein the substrate is adapted to possess a light influencing property.

14. The optical element as claimed in claim 13 wherein the substrate is adapted to possess photochromism.
15. The optical element as claimed in claim 13 wherein the light influencing property is integral to the substrate.

16. The optical element as claimed in claim 13 wherein a light influencing compound is contained in a coating or treatment applied to a surface of the substrate.
17. The optical element as claimed in claim 1 or 2, wherein the resinous material of i) comprises an acrylic polymer, a polyester polymer, a polyurethane polymer, a polycarbonate polymer, and/or a polyether polymer.
18. The optical element as claimed in claim 1 or 2, wherein the resinous material of i) comprises a (meth)acrylic monomer.
19. The optical element as claimed in claim 1 or 2, wherein the curing agent of ii) comprises an aminoplast resin, a polyisocyanate, a blocked polyisocyanate, a polyepoxide, a polyacid, an anhydride, a polyanhydride, a polyethylenically unsaturated material, and/or a polyol.
20. The optical element as claimed in claim 1 or 2, wherein the material of iii) comprises a trialkoxysilylpropyl isocyanate.
21. The optical element as claimed in claim 20, wherein the material of iii) comprises triethoxysilylpropyl isocyanate blocked with 3,5-dimethylpyrazole, and/or trimethoxysilylpropyl isocyanate blocked with 3,5-dimethylpyrazole.

Documents:

1991-DELNP-2008-1-Correspondence Others-(20-06-2012).pdf

1991-delnp-2008-1-Correspondence-Others-(10-10-2012).pdf

1991-delnp-2008-1-GPA-(10-10-2012).pdf

1991-delnp-2008-Abstract-(11-10-2012).pdf

1991-DELNP-2008-Abstract-(20-06-2012).pdf

1991-delnp-2008-abstract.pdf

1991-delnp-2008-Claims-(11-10-2012).pdf

1991-DELNP-2008-Claims-(20-06-2012).pdf

1991-delnp-2008-Claims-Marked-(11-10-2012).pdf

1991-delnp-2008-claims.pdf

1991-delnp-2008-Correspondence Others-(13-05-2013).pdf

1991-delnp-2008-Correspondence Others-(12-09-2014).pdf

1991-delnp-2008-Correspondence Others-(18-12-2013).pdf

1991-delnp-2008-Correspondence Others-(19-09-2013).pdf

1991-delnp-2008-Correspondence Others-(19-12-2013).pdf

1991-delnp-2008-Correspondence Others-(20-06-2012).pdf

1991-DELNP-2008-Correspondence Others-(23-11-2011).pdf

1991-delnp-2008-Correspondence Others-(25-05-2012).pdf

1991-delnp-2008-Correspondence Others-(26-02-2013).pdf

1991-DELNP-2008-Correspondence Others-(30-10-2013).pdf

1991-delnp-2008-Correspondence-IPO-(05-11-2012).pdf

1991-delnp-2008-correspondence-others (14-05-2010).pdf

1991-delnp-2008-Correspondence-Others-(01-07-2013).pdf

1991-delnp-2008-Correspondence-Others-(03-07-2013).pdf

1991-DELNP-2008-Correspondence-Others-(10-10-2012).pdf

1991-delnp-2008-Correspondence-Others-(11-10-2012).pdf

1991-delnp-2008-Correspondence-Others-(12-07-2013).pdf

1991-delnp-2008-Correspondence-Others-(13-06-2013).pdf

1991-delnp-2008-Correspondence-Others-(19-08-2013).pdf

1991-delnp-2008-Correspondence-Others-(24-01-2013).pdf

1991-delnp-2008-Correspondence-Others-(26-09-2012).pdf

1991-delnp-2008-correspondence-others.pdf

1991-delnp-2008-description (complete).pdf

1991-delnp-2008-Form-1-(11-10-2012).pdf

1991-delnp-2008-form-1.pdf

1991-delnp-2008-form-18 (14-05-2010).pdf

1991-delnp-2008-Form-2-(11-10-2012).pdf

1991-delnp-2008-form-2.pdf

1991-delnp-2008-Form-3-(03-07-2013).pdf

1991-delnp-2008-Form-3-(12-09-2014).pdf

1991-delnp-2008-Form-3-(18-12-2013).pdf

1991-DELNP-2008-Form-3-(23-11-2011).pdf

1991-delnp-2008-Form-3-(25-05-2012).pdf

1991-delnp-2008-form-3.pdf

1991-delnp-2008-form-5.pdf

1991-delnp-2008-pct-101.pdf

1991-delnp-2008-pct-210.pdf

1991-delnp-2008-pct-304.pdf

1991-delnp-2008-Petition-137-(20-06-2012).pdf


Patent Number 264225
Indian Patent Application Number 1991/DELNP/2008
PG Journal Number 51/2014
Publication Date 19-Dec-2014
Grant Date 16-Dec-2014
Date of Filing 07-Mar-2008
Name of Patentee TRANSITIONS OPTICAL, INC.
Applicant Address 9251 BELCHER ROAD, PINELLAS PARK, FL 33782, U.S.A
Inventors:
# Inventor's Name Inventor's Address
1 STEWART, KEVIN, J 1207 MURRYSVILLE CHASE LANE, MURRYSVILLE, PA 15668, U.S.A
PCT International Classification Number C08G 18/71
PCT International Application Number PCT/US2006/033520
PCT International Filing date 2006-08-29
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 11/221,188 2005-09-07 U.S.A.