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US20170031059A1 - Polymer Composition and Methods Using Said Polymer Composition to Manufacture Ophthalmic Lens - Google Patents

Polymer Composition and Methods Using Said Polymer Composition to Manufacture Ophthalmic Lens Download PDF

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Publication number
US20170031059A1
US20170031059A1 US15/106,617 US201315106617A US2017031059A1 US 20170031059 A1 US20170031059 A1 US 20170031059A1 US 201315106617 A US201315106617 A US 201315106617A US 2017031059 A1 US2017031059 A1 US 2017031059A1
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United States
Prior art keywords
monomer
ophthalmic lens
composition
oligomer
polymer composition
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US15/106,617
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English (en)
Inventor
Robert Valeri
John Biteau
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EssilorLuxottica SA
Original Assignee
Essilor International Compagnie Generale dOptique SA
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Publication date
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Assigned to ESSILOR INTERNATIONAL (COMPAGNIE GENERALE D'OPTIQUE) reassignment ESSILOR INTERNATIONAL (COMPAGNIE GENERALE D'OPTIQUE) ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BITEAU, JOHN, VALERI, ROBERT
Publication of US20170031059A1 publication Critical patent/US20170031059A1/en
Assigned to ESSILOR INTERNATIONAL reassignment ESSILOR INTERNATIONAL ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Essilor International (Compagnie Générale d'Optique)
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
    • G02B1/041—Lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/112—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
    • B29C64/135—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
    • B29C67/0059—
    • B29C67/0066—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00028—Bifocal lenses; Multifocal lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00432—Auxiliary operations, e.g. machines for filling the moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00432—Auxiliary operations, e.g. machines for filling the moulds
    • B29D11/00442—Curing the lens material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/0048—Moulds for lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F20/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride, ester, amide, imide or nitrile thereof
    • C08F20/02—Monocarboxylic acids having less than ten carbon atoms, Derivatives thereof
    • C08F20/10—Esters
    • C08F20/12—Esters of monohydric alcohols or phenols
    • C08F20/16—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms
    • C08F20/18—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms with acrylic or methacrylic acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L101/00—Compositions of unspecified macromolecular compounds
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
    • G02B1/041—Lenses
    • G02B1/043—Contact lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
    • B29K2105/0014—Catalysts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B29L2011/0016—Lenses
    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00—Optical parts
    • G02C7/02—Lenses; Lens systems ; Methods of designing lenses
    • G02C7/022—Ophthalmic lenses having special refractive features achieved by special materials or material structures

Definitions

  • the present invention relates to polymer composition of manufacturing ophthalmic lens, to methods of manufacturing an ophthalmic lens comprising said polymer composition and to ophthalmic lens obtained by said methods.
  • Plastic ophthalmic lenses are well known and have a common usage.
  • thermoplastic lenses are obtained through an injection process and thermosetting lenses are obtained through a casting process.
  • Thermosetting polymer represents a polymer network formed by the chemical reaction of monomers, at least one of which has two or more reactive groups per molecule (that means a functionality equal to or higher than two), and that presents in relative amounts such that a gel is formed as a particular conversion during the synthesis.
  • thermosetting polymer is formed in an irreversible way, the synthesis of a thermosetting polymer is carried out to produce final material with the desired shape. Therefore, polymer and final shaping are performed in the same process.
  • monomers used to obtaine such material are casted between two molds having the required surface geometries.
  • the number of combination of surface geometries needed in the ophthalmic lens is too broad to have one specific mold for one specific lens in accordance with the prescription of a wearer, and/or in accordance with the geometry of the frame wherein said lens will be mounted.
  • ophthalmic lens are manufactured through a subtractive process, wherein firstly the lens is casted has a round shape as a semi-finished lens or finished lens, and then this round shape submit various steps like surfacing and edging to provide a final lens (with less polymer material than the initial lens round shape) adapted to the prescription of a wearer and adapted to be mounted to a frame choice by said wearer. So part of initial thermosetting material is loss and this consumption of material represent economical and environment issue.
  • Additive Manufacturing methods and devices have become well-known in various industries for production of parts and products formerly manufactured using subtractive manufacturing techniques, such as traditional machining. Application of such manufacturing methods has not been systematically applied.
  • additive manufacturing means a manufacturing technology as defined in the international standard ASTM 2792-12, which mentions a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies, such as traditional machining.
  • Additive manufacturing technologies comprise processes which create objects by juxtaposition of volume elements according to a pre-determined arrangement that can be defined in a CAD (Computer Aided Design) file. Such juxtaposition is understood as the result of sequential operations such as building a material layer on top of a previously obtained material layer and/or juxtaposing a material volume element next to a previously obtained volume element.
  • CAD Computer Aided Design
  • the primary advantage of this technique is its ability to create almost any shape or geometric feature.
  • using such additive manufacturing methods provides much more freedom during the determining step.
  • shrinkage Another disadvantage of polymerizable composition used usually to traditional ophthalmic industry is linked to the shrinkage phenomenon.
  • shrinkage could be defined as a reduction in the size of a part after it has changed from a liquid state to a solid state. So for polymer composition obtained by polymerization of polymerizable composition, during the curing cycle, the thermoset undergoes the residual deformation and stresses due to shrinkage of matrix. This shrinkage may have a thermal and/or chemical origin. The chemical shrinkage is a direct consequence of crosslinking of the thermosetting polymer.
  • ophthalmic lenses When polymerizable composition shrink, materials of the objects can change their fundamental properties.
  • the shrinkage can cause change in geometry and shrinking of a part of the object will also induce internal stress buildup.
  • Objects having an internal stress buildup tend toward a more relaxed state by changing their geometry. This is especially problematic when manufacturing products, such as ophthalmic lenses.
  • the geometric configuration of an ophthalmic lens comprises a first surface and a second surface that can have complex curvatures. Any shrinkage or distortion of these curvatures could affect the optical property of the lens.
  • the physical constitution of voxels in additive manufacturing technologies classically uses physical means to induce geometry variations in the voxels during the fabrication process.
  • the physical means may include introducing light and/or thermal variations.
  • said means typically generate dimensional shrinkage at the scale of individual voxels, and also macroscopic stress building at the scale of the object produced by the additive manufacturing process.
  • the polymerizable composition comprised 2 different categories of monomers which are able during crosslinking to control and limit said chemical shrinkage.
  • monomer or oligomer (A) is present from 99% to 1% by weight of the total weight of polymerizable composition and monomer (B) is present from 1% to 99% by weight of the total weight of polymerizable composition.
  • Monomer (B) possesses a cyclic group which could be monocyclic, or polycyclic, substituted or unsubstituted, without aromaticity properties, said cyclic group being selected from cyclic sulfates, spiroorthoesters, bicyclic-ortho esters, cyclic carbonates, spiroorthocarbonates, bicyclic ketal lactones, and combinations thereof.
  • At least part of reactive group of monomer or oligomer (A) reacts with at least part of reactive group of monomer (B) after the opening step of the cyclic group, to form a copolymer of monomer (A) and (B) during polymerization process.
  • reactive group of monomer or oligomer (A) reacts only with reactive group of another molecule of monomer or oligomer (A) to form a homopolymer (A) during polymerization process; and reactive group resulting from the opening of the cyclic part of monomer (B) reacts only with reactive group of another molecule of monomer (B) to form a homopolymer (B) during polymerization process; and no phase separation appears between homopolymer (A) and homopolymer (B) to the resulting polymer composition of the invention.
  • the ratio of monomer (B) to monomer or oligomer (A) is increased proportionally with the increasing number of reactive groups present in each monomer or oligomer (A).
  • the polymer composition according to the invention comprises an amount of monomer (B) to reduce the shrinkage of said polymer composition to less than 5%, preferably less than 2% and most preferably around 0%.
  • the invention comprises also a method of manufacturing an ophthalmic lens characterized in that the polymer composition according to the invention is manufactured by an additive manufacturing process comprising the following steps:
  • a first treatment increases the viscosity of the voxels such that they substantially remain where deposited and have sufficient cohesion to support later-deposited voxels.
  • a second voxel or group of voxels
  • monomer and/or oligomer from the first voxel (or group of voxels) diffuse into the second voxel (or group of voxels) either spontaneously or under application of a second treatment.
  • the second treatment can optionally polymerize or increase the viscosity of the resulting combination of voxels.
  • said three mains actions may be achieved voxel-to-voxel, line-to-line, layer-by-layer, and/or after all desired layers have been formed to produce said three-dimensional transparent ophthalmic lens.
  • the transparent ophthalmic lens manufactured by a method in accordance of any previous embodiments may further be treated to obtain an ophthalmic lens with at least one added value. Then in accordance with this, the invention comprises a method comprising further step(s):
  • the transparent ophthalmic lens represents an ophthalmic lens selected from blank lens, semi-finished lens, finished lens, and lens adapted to see-trough “Head-Mounting Display” (HMD).
  • HMD Head-Mounting Display
  • Head mounting display it is understood a device able to be mounted on the head of a wearer, and comprising an optical imager for shaping light beams coming from an electronic and optical system that generates light beams from an electronic signal, the system being of the miniature screen, laser diode, or light-emitting diode (LED) type; the optical imager directing light beams towards the eye of the wearer so as to enable an information content to be used.
  • LED light-emitting diode
  • Said transparent ophthalmic lens may also represent a lens selected from afocal (or no-corrective, or plano), unifocal, bifocal, trifocal, and progressive lens, said ophthalmic lens being able to be mounted either to traditional frame comprising two distinctive ophthalmic lenses, one for the right eye and one for the left eye, or to mask, visor, helmet sight or goggle, wherein one ophthalmic lens facing simultaneously the right and the left eyes, and said ophthalmic lens may be produced with traditional geometry as a circle or may be produced to be fitted to the geometry to the frame intended.
  • said ophthalmic lens When said ophthalmic lens is dedicated to be mounted to a see-trough “HMD”, said lens may be corrective or afocal, and may be placed on the front face and/or on the rear face of the optical imager of the HMD. When the ophthalmic lens is placed on the front face and on the rear face of the optical imager, it means that the optical imager is inserted inside said ophthalmic lens.
  • Transparent ophthalmic lens obtained from a method of at least one mentioned embodiment is also an object of the present invention.
  • compositions comprising a component does not exclude it from having additional components
  • an apparatus comprising a part does not exclude it from having additional parts
  • a method having a step does not exclude it having additional steps.
  • compositions, apparatuses, and methods that “consist essentially of” or “consist of” the specified components, parts, and steps are specifically included and disclosed.
  • the words “consisting essentially of,” and all grammatical variations thereof are intended to limit the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic(s) of the claimed invention.
  • any number and any range falling within the range is also intended to be specifically disclosed.
  • every range of values in the form “from a to b,” or “from about a to about b,” or “from about a to b,” “from approximately a to b,” and any similar expressions, where “a” and “b” represent numerical values of degree or measurement) is to be understood to set forth every number and range encompassed within the broader range of values, and including the values “a” and “b” themselves.
  • Terms such as “first,” “second,” “third,” etc. may be assigned arbitrarily and are merely intended to differentiate between two or more components, parts, or steps that are otherwise similar or corresponding in nature, structure, function, or action.
  • the words “first” and “second” serve no other purpose and are not part of the name or description of the following name or descriptive terms.
  • the mere use of the term “first” does not require that there be any “second” similar or corresponding component, part, or step.
  • the mere use of the word “second” does not require that there be any “first” or “third” similar or corresponding component, part, or step.
  • first does not require that the element or step be the very first in any sequence, but merely that it is at least one of the elements or steps.
  • second does not necessarily require any sequence. Accordingly, the mere use of such terms does not exclude intervening elements or steps between the “first” and “second” elements or steps, etc.
  • “Additive Manufacturing” means manufacturing technology as defined in the international standard ASTM 2792-12, describing a process of joining materials to make 3-D solid objects from a 3-D digital model. The process is referred to as “3-D printing” or “materials printing” since successive layers are laid down atop one another. Printing materials include liquids, powders, and sheet materials, from which series of cross-sectional layers are built. The layers, which correspond to the virtual cross sections from the CAD model, are joined or automatically fused to create the solid 3-D object.
  • Additive Manufacturing includes, but is not limited to, manufacturing methods such as stereolithography, mask stereolithography, mask projection stereolithography, polymer jetting, scanning laser sintering (SLS), scanning laser melting (SLM), and fused deposition modelling (FDM).
  • Additive Manufacturing technologies comprise processes which create 3-D solid objects by juxtaposition of volume elements or particles according to a pre-determined arrangement, typically defined in a CAD (Computer Aided Design) file. Juxtaposition is understood as sequential operations including building one material layer on top of a previously built material layer, and/or positioning a material volume element next to a previously deposited material volume element.
  • One such additive manufacturing method employs a printer head such as in an ink-jet or polymer-jet printer that deposits discrete units (voxels) of a composition onto a substrate or previously deposited voxel.
  • the voxels are typically deposited as layers, with successive layers inter-diffused and converted to a geometrically stable voxel composition.
  • jet printing a critical step is maintaining voxel shape.
  • the voxel shape is then converted to a homogenous solid by UV or thermal curing, for example.
  • Another method involves a pool or bath of polymerizable composition as a curable liquid.
  • a selected cross-section of a layer of the polymerizable composition is cured, such as by exposure to UV radiation.
  • An additional layer of the curable liquid is then constituted or deposited onto the first layer, and the process is gradually repeated, building-up the desired three-dimensional solid element.
  • This technology is well known as stereolithography and its derivatives.
  • voxel means a volume element.
  • a voxel is a distinguishable, geometric shape which is part of a three-dimensional space.
  • voxel can refer to an individual element which, in combination with other voxels, defines an intermediate element which could be a layer of within the space.
  • the term “voxel,” as used herein can apply to an intermediate element which is part of the three-dimensional space. That is, a single voxel can comprise a layer of the three-dimensional space, more particularly when the additive manufacturing technology used is based on stereolithography technologies.
  • a particular voxel may be identified by x, y, and z coordinates of a selected point of geometry of the shape, such as a corner, centre, etc., or by other means known in the art.
  • an ophthalmic lens is understood to be transparent when the observation of an image through said ophthalmic lens is perceived with no significant loss of contrast, that is, when the formation of an image through said ophthalmic lens is obtained without adversely affecting the quality of the image.
  • This definition of the term “transparent” can be applied, within the terms of reference of the invention, to all objects qualified as such in the description.
  • polymerization/polymerizing/polymerizable refers to a chemical reaction that produces bonding of two or more monomers and/or oligomers to form a polymer.
  • Polymerization and all grammatical variations include photo-polymerizable and/or thermo-polymerizable compositions.
  • Photo-polymerizable means polymerization which occurs by exposing a composition to activating light.
  • Thermo-polymerizable means polymerization which occurs by exposing the composition to a variation of temperature.
  • curing refers to a chemical process of converting a monomer or a oligomer into a polymer of higher molar mass and then into a network.
  • “monomer” and/or “oligomer” refer to a chemical compound comprising at least a reactive group able to react to activating light, and/or temperature in the presence of an initiator. More details relating to “reactive group” being involved will be described latter in the present specifications.
  • activating light refers to actinic radiation and visible light. Activating light may affect a chemical change. Activating light may include ultraviolet light (e.g., light having a wavelength between about 280 nm to about 400 nm), actinic light, visible light or infrared light. Generally, any wavelength of light capable of affecting a chemical change may be classified as activating. Chemical changes may be manifested in a number of forms. A chemical change may include, but is not limited to, any chemical reaction that causes a polymerization to take place.
  • an initiator represents a photo-initiator or a thermo-initiator.
  • a photo-initiator represents a molecule employed alone or in a chemical system (involving two or more molecules) that absorbs light and forms reactive initiating species. Then by absorption of light, a photo-initiator generates reactive species (ion or radical) and initiates a chemical reaction or transformation.
  • a co-initiator represents a molecule as part of a chemical system which does not absorb light but, nevertheless, participates in the production of the reactive species.
  • the polymer composition according to the invention can also contain additives used conventionally in compositions intended for manufacturing ophthalmic elements, in standard proportions, namely, inhibitors, dyes, UV absorbers, fragrances, deodorants, surface active agents, surfactants, binders, antioxidants, optical-brigthner and anti-yellowing agents.
  • inter-diffuse means movement of at least an ion, molecule, portion of a molecule, or portion of a polymer chain, from the space occupied by one voxel into the space occupied by a juxtaposed, physically contacting, voxel.
  • Inter-diffusion can occur spontaneously or be induced by mechanical, physical, or chemical treatment.
  • a mechanical treatment includes agitation, such as by exposure to ultra-sonic energy, high-frequency vibratory device, etc., which promote mixing at the voxel boundaries.
  • Macro-diffusion is a mechanical method wherein the voxels are blended or “smeared” by table vibrations, especially where such vibrations occur at the time of deposition, resulting in intimate voxel-to-voxel contact.
  • An exemplary physical treatment includes a thermal treatment by exposure to heat, infra-red, microwave, etc., radiation. A thermal treatment increases temperature above the glass-liquid transition point (Tg) of the high viscosity domain in the voxels and promotes inter-diffusion.
  • An exemplary chemical treatment includes a chemical reaction between reactive species of composition. The molecular mass of the polymers present in the voxels can be reduced, such as by two-pathway chemistries or reversible reactions, to promote inter-diffusion.
  • the polymer composition according to the invention comprises at least a monomer (B), said monomer (B) expands during polymerization.
  • an expanding monomer is one that exhibits expansion in volume during ring opening polymerization.
  • the monomeric volume of the composition may be maintained during polymerization or may be only minimally changed during polymerization or may be only negligibly changed during polymerization.
  • the volume after polymerization of a composition comprising an expanding monomer is either maintained (e.g., with near zero shrinkage) or only minimally reduced or only negligibly reduced.
  • the shrinkage of a composition containing an expanding monomer may be less than about 5% or less than about 4% or less than about 3% or less than about 2% or most preferably around 0%.
  • the monomers (B) disclosed herein are capable of expanding their volume after polymerization.
  • Monomers (B) comprised at least a non-aromatic cyclic group such as cyclic carbonates or bicyclic monomers with fused rings (having at least one carbon atom in common) that maintain or expand their volume during polymerization due to an opening of strained rings.
  • Bicyclic expanding monomers exhibit a double ring opening during polymerization, such that for every shift from a van der Waals bond to a covalent bond, which occurs during polymerization, there are two covalent bonds that are broken. This is in contrast with conventional monomers (or oligomers) that shrink during polymerization, which leads to a negative change in volume, which is sometimes quite significant. Conventional monomers or oligomers also undergo a one-to-one replacement of one van der Waals attraction with one covalent bond during polymerization.
  • Catalysis (polymerization) of an expanding monomer is generally initiated by a Lewis acid (e.g., cationic-induced ring opening or anionic-induced ring opening) or a free-radical initiating agent. Catalysis often occurs in the absence of a solvent. A solvent may be included depending on the selection of any additional monomer(s) or oligomer(s) present in the initial polymerizable composition.
  • a reaction promoter capable of accelerating polymerization, may be added (e.g., polyol) to the initial polymerizable composition.
  • Polymerization of expanding monomers (B) may also be initiated in the presence of light, such as visible light or ultraviolet (UV) light; hence, said expanding monomers are often photopolymerizable.
  • many expanding monomers (B) are temperature sensitive, such that the temperature during polymerization directly affects the degree of expansion.
  • monomer (B) comprises a non-aromatic cyclic group, which may be monocyclic or polycyclic, substituted or unsubstituted.
  • monocyclic group it is understood a cycle carbon chain comprising from 5 to 12 atoms to said chain, wherein 1 to 4 carbon atom could be replaced by a group selected from O, N, CO, S, SO, or SO 2 and wherein 1 to 3 single carbon-carbon bond of the cycle chain could be replaced by carbon-carbon double bonds.
  • polycyclic group it is understood a group comprising 1, 2 or 3 cycles, each cycle being from 3 to 8 members, each cycle being fused together or bond together by at least one common atom, wherein 1 to 6 carbon atom of the polycyclic chain may be replaced by a group selected from O, N, CO, S, SO, or SO 2 and wherein 1 to 4 single carbon-carbon bond of the polycyclic chain may be replaced by carbon-carbon double bonds.
  • Such monocyclic group is represented for example by the following structure: cyclopentyl, cyclohexyl, cycloheptyl, azirine, oxyrane, thiiranes, oxetane, oxelane, imidazoline, imidazolidine, morpholine, piperazine, piperidine, pyrazolidine, pyrrolidine, and the like.
  • Such polycyclic group may be for example derivative of quinuclidine, oxaspiro[4,5]decane, 3,9-dioxaspiro[5,5]undecane, dispiro[4.2.4.2]tetradecane, spiro[4.4]nona-2,7-diene, . .
  • Monomer (B) represents a fused bicyclic rings, and more particularly wherein said ring of the bicyclic have at least one common atom (spiro structure), each ring contains at least one atom of another element than carbon, and the ring do not open in a symmetrical manner.
  • an oxygen atom in one ring may from a carbonyl group while the corresponding oxygen in the other ring would form an ether group.
  • Monocyclic or polyclyclic group of monomer (B) may be unsubstituted or comprised from 1 to 6 substituents, identical or different, independently of each other, selected from C 1 -C 6 alkyl, C 1 -C 6 alkenyl, C 1 -C 6 alkoxy, halo, hydroxy, selected from halogen, —R a , —OH, —OR a , —SH, —SR a , —NH 2 , —NR a R a1 , —CO—R a , —CO 2 R a1 , wherein R a and R a1 identical or different represent a group selected from C 1 -C 10 alkyl wherein a carbon-carbon bond may be replaced by at least one carbon-carbon double bond, and/or from 1 to 3 carbon atom may be replaced by an oxygen atom, a sulphur atom or a carbonyl group.
  • Suitable monomer (B), as described herein, will include preferentially, but are not limited to, cyclic sulfates, spiroorthoesters, bicyclic-ortho esters, cyclic carbonates, spiroorthocarbonates, norbornene spiroorthocarbonates, bismethylene spiroorthocarbonates and bicyclic ketal lactones.
  • a cyclic sulfate will have the general structure, as provided below, before ring opening (25) and after ring opening (26, 27).
  • a cyclic carbonate will have the general structure, as provided below, before (20) ring opening and after (21, 22) ring opening.
  • a bicyclic-ortho ester will have the general structure, as provided below, before (left) a double ring opening and after (right) a double ring opening.
  • a spyro-ortho ester will have the general structure, as provided below, before (left) a
  • Polymerization with expansion in volume can be achieved with spiroorthocarbonate monomers through a double ring-opening process wherein two bonds are cleaved for each new bond formed.
  • Monomer or oligomer (A) of the polymerizable composition to provide the polymer composition in accordance with the invention comprises at least a reactive group selected from epoxy, thioepoxy, epoxysilane, (meth)acrylate, thio(met)acrylate, vinyl, urethane, thiourethane, isocyanate, mercapto and alcohol.
  • a reactive group selected from epoxy, thioepoxy, epoxysilane, (meth)acrylate, thio(met)acrylate, vinyl, urethane, thiourethane, isocyanate, mercapto and alcohol.
  • Monomers/oligomer (A) comprising at least an epoxy/thioepoxy reactive group are classified as either aromatic (such as bisphenol A and F epoxies) or aliphatic. Aliphatic epoxies are lower in viscosity. Aliphatic epoxies can be both completely saturated hydrocarbons (alkanes) or can contain double or triple bonds (alkenes or alkynes). They can also contain rings that are not aromatic. Epoxy may be also monofunctional or polyfunctional, and such epoxy may be from the family of alkoxysilane epoxy.
  • Non-alkoxysilane polyfunctional epoxy monomers may be selected from the group consisting of diglycerol tetraglycidyl ether, dipentaerythritol tetraglycidyl ether, sorbitol polyglycidyl ether, polyglycerol polyglycidyl ether, pentaerythritol polyglycidyl ether such as pentaerythritol tetraglycidyl ethertrimethylolethane triglycidyl ether, trimethylolmethane triglycidyl ether, trimethylolpropane triglycidyl ether, triphenylolmethane triglycidyl ether, trisphenol triglycidyl ether, tetraphenylol ethane triglycidyl ether, tetraglycidyl ether of tetraphenylol ethane,
  • the monoepoxysilanes are commercially available and include, for example, beta-(3,4-epoxycyclohexyl)-ethyltrimethoxysilane, (gamma-g lycidoxypropyltrimethoxysi lane), (3-glycidoxypropyl)-methyl-diethoxysilane, and gamma-glycidoxy-propylmethyldimethoxysilane.
  • These commercially available monoepoxysilanes are listed solely as examples, and are not meant to limit the broad scope of this invention.
  • alkyltrialkoxysilane or tetraalkoxysilane suitable for the present invention include methyltrimethoxysilane, ethyltrimethoxysilane, phenyltrimethoxysilane.
  • Monomers/oligomers (A) of the invention may comprise (meth)acrylate or thio(meth)acrylate reactive group.
  • acrylate and acrylic referred to the same chemical functionality.
  • the word “meth” in two brackets as “(meth)” associated to the term acrylate, specifies that relating to a molecule or to a family of molecules the acrylate function H 2 C ⁇ CHC(O)— could have a methyl group at position of the ethylene function like H 2 C ⁇ C(CH 3 )C(O)—.
  • (Meth)acrylates can be monofunctional, difunctional, trifunctional, tetrafunctional, pentafunctional, and even hexafunctional. Typically, the higher the functionality, the greater is the crosslink density. (Meth)acrylates have slower curing than the acrylates.
  • R1, R2, R′ and R′′ represent, independently of one another, a hydrogen atom or a methyl radical
  • Ra and Rb which are identical or different, each represent an alkyl group having 1 to 10 carbon atoms
  • m and n are integers wherein m+n is comprised between 2 to 20 inclusive.
  • composition comprising this (meth)acrylic monomer can comprise other monomer(s) polymerizable by a radical route, and presenting one or more (meth)acrylate functional groups and/or one or more allyl groups.
  • monomers of poly(methylene glycol) mono- and di(meth)acrylates, poly(ethylene glycol) mono- and di(meth)acrylates, poly(propylene glycol) mono- and di(meth)acrylates, alkoxypoly(methylene glycol) mono-and di(meth)acrylates [sic], alkoxypoly(ethylene glycol) mono- and di(meth)acrylates [sic] and poly(ethylene glycol)-poly(propylene glycol) mono- and di(meth)acrylates.
  • These monomers are disclosed, inter alia, in the document U.S. Pat. No. 5,583,191.
  • poly(ethylene glycol) dimethacrylate [sic] for example, poly(ethylene glycol-600) dimethacrylate, poly(propylene glycol) dimethacrylate [sic] (for
  • the polymerizable composition according to the invention and comprising such (meth)acrylate monomer and/or oligomer also comprises a system for initiating the polymerization.
  • the polymerization initiating system can comprise one or more thermal or photochemical polymerization initiating agents or alternatively, preferably, a mixture of thermal and photochemical polymerization initiating agents.
  • the initiating agents are used in a proportion of 0.01 to 5% by weight with respect to the total weight of monomers present in the composition.
  • the composition more preferably simultaneously comprises a thermal polymerization initiating agent and a photoinitiator.
  • the present invention can notably use functional monomers of mono(thio)(meth)acrylate or mono- and di(meth)acrylate type bearing a 5- to 8-membered heterocycle consisting of hydrogen, carbon and sulphur atoms and having at least two endocyclic sulphur atoms.
  • the heterocycle is 6- or 7-membered, better still 6-membered.
  • the number of endocyclic sulphur atoms is 2 or 3.
  • the heterocycle can optionally be fused with a substituted or unsubstituted C5-C8 aromatic or polycyclanic ring, preferably a C6-C7 ring.
  • the heterocycle of the functional monomers contains 2 endocyclic sulphur atoms, these endocyclic sulphur atoms are preferably in positions 1-3 or 1-4 of the heterocycle.
  • the monomer is preferably also a thio(meth)acrylate monomer.
  • the monomers according to the invention preferably have molar masses of between 150 and 400, preferably 150 and 350 and better still between 200 and 300. Example of such monomers is described in the document U.S. Pat. No. 6,307,062 which is incorporated by reference.
  • the polymerizable composition comprising such thio(meth)acrylate monomers may comprise a co-monomer.
  • co-monomers which can be used with the monomers (A) of (thio)(meth)acrylate type for polymerizable compositions according to the invention, mention may be made of mono- or polyfunctional vinyl, acrylic and methacrylic monomers.
  • vinyl co-monomers which are useful in the compositions of the present invention, mention may be made of vinyl alcohols and vinyl esters such as vinyl acetate and vinyl butyrate.
  • the acrylic and methacrylic co-monomers can be mono- or polyfunctional alkyl (meth)acrylate co-monomers and polycyclenic or aromatic mono(meth)acrylate co-monomers.
  • alkyl (meth)acrylates mention may be made of styrene, .alpha.-alkylstyrenes such as .alpha.-methyl styrene, methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, isobutyl (meth)acrylate or difunctional derivatives such as butanediol dimethacrylate, or trifunctional derivatives such as trimethylolpropane trimethacrylate.
  • styrene .alpha.-alkylstyrenes such as .alpha.-methyl styrene, methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, isobutyl (meth)acrylate or difunctional derivatives such as butanediol dimethacrylate, or trifunctional derivatives such as trimethylolpropane trimethacrylate.
  • polycyclenic mono(meth)acrylate co-monomers mention may be made of cyclohexyl (meth)acrylate, methylcyclohexyl (meth)acrylate, isobornyl (meth)acrylate and adamantyl (meth)acrylate.
  • Co-monomers which may also be mentioned are aromatic mono(meth)acrylates such as phenyl (meth)acrylate, benzyl (meth)acrylate, 1-naphthyl (meth)acrylate, fluorophenyl (meth)acrylate, chlorophenyl (meth)acrylate, bromophenyl (meth)acrylate, tribromophenyl (meth)acrylate, methoxyphenyl (meth)acrylate, cyanophenyl (meth)acrylate, biphenyl (meth)acrylate, bromobenzyl (meth)acrylate, tribromobenzyl (meth) acrylate, bromobenzylethoxy(meth)acrylate, tribromobenzylethoxy(meth)acrylate and phenoxyethyl (meth)acrylate.
  • aromatic mono(meth)acrylates such as phenyl (meth)acrylate, benzyl (meth)acrylate,
  • the crosslinking process which is particularly suitable for polymerizable composition based on thio(meth)acrylate alone or in combination with at least one co-monomer, as defined hereinbefore, are photochemical polymerization or a combination of a photochemical polymerization and a thermal condensation reaction.
  • a recommended polymerization process is photochemical polymerization via ultraviolet radiation and preferably UV-A radiation.
  • the composition also contains photo-initiators and/or condensation catalysts.
  • photo-initiators and/or thermal catalyst are present in proportions of from 0.001 to 5% by weight relative to the total weight of the composition, and even more preferably from 0.01 to 3.5%.
  • the photo-initiators which can be used in composition according to the invention are, in particular, 2,4,6-trimethylbenzoyldiphenylphosphine oxide, 1-hydroxycyclohexyl phenyl ketone, 2,2-dimethoxy-1,2-diphenyl-1-ethanone and alkylbenzoin ethers.
  • Vinyl ether group presents as reactive group to monomer or oligomer (A) is also suitable.
  • Example of such compound comprising this functionality are ethyl vinyl ether, propyl vinyl ether, isobutyl vinyl ether, cyclohexyl vinyl ether, 2-ethyl hexyl vinyl ether, butyl vinyl ether, ethylenglycol monovinyl ether, diethyleneglycol divinyl ether, butane diol divinyl ether, hexane diol divinyl ether, cyclohexane dimethanol monovinyl ether
  • polyisocyanate or isothiocyanate monomers or oligomers (A) suitable in accordance with the present invention there may be cited tolylene diisocyanate or diisothiocyanate, phenylene, diisocyanate or diisothiocyanate, ethylphenylene diisocyanate or diisothiocyanate, isopropyl phenylene diisocyanate or diisothiocyanate, dimethylphenylene diisocyanate or diisothiocyanate, diethylphenylene diisocyanate or diisothiocyanate, diisopropylphenylene diisocyanate or diisothiocyanate, trimethylbenzyl triisocyanate or triisothiocyanate, xylylene diisocyanate or diisothiocyanate, benzyl triiso(thio)cyanate, 4,4′-diphenyl methane diisocyanate or diis
  • aliphatic polythiols such as pentaerythritol tetrakis mercaptopropionate, 1-(1′-mercaptoethylthio)-2,3-dimercaptopropane, 1-(2′-mercapropylthio)-2,3-dimercaptopropane, 1-(3′-mercapropylthio)-2,3-dimercaptopropane, 1-(4′-mercabutylthio)-2,3-dimercaptopropane, 1-(5′-mercapentylthio)-2,3-dimercaptopropane, 1-(6′-mercahexylthio)-2,3-dimercaptopropane, 1, 2-bis-(4′-mercapto
  • Photo-initiator may be used alone or in a mixture of two or more compounds, or as a combination or two or more compounds like co-initiators.
  • the choice of photo-initiator is based firstly to the nature of reactive group(s) of monomer or oligomers (A) and monomer (B) used in the polymerizable composition and also to the kinetic of polymerization. Then it is well-known that cationic curable compositions cure slower than free radically curable compositions. In term of methods used in accordance with the various embodiments of the invention, the man skilled in the art will adapt easily the choice of such photoinitiator.
  • Free radical initiator suitable for the present invention are listed below, without any limitation: benzophenone, methyl benzophenone, xanthones, acylphosphine oxide type such as 2,4,6,-trimethylbenzoyldiphenyl phosphine oxide, 2,4,6,-trimethylbenzoylethoxydiphenyl phosphine oxide, bisacylphosphine oxides (BAPO), benzoin and benzoin alkyl ethers like benzoin methyl ether, benzoin isopropyl ether.
  • acylphosphine oxide type such as 2,4,6,-trimethylbenzoyldiphenyl phosphine oxide, 2,4,6,-trimethylbenzoylethoxydiphenyl phosphine oxide
  • BAPO bisacylphosphine oxides
  • benzoin and benzoin alkyl ethers like benzoin methyl ether, benzoin isopropyl ether.
  • Free radical photo-initiators can be selected also for example from haloalkylated aromatic ketones such as chloromethylbenzophenones; some benzoin ethers such as benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin isobutylether ether, benzoin, benzyl, benzyl disulfide; dialkoxyacetophenones such as diethoxyacetophenone and ⁇ , ⁇ -dimethoxy- ⁇ -phenylacetophenone, benzylideneacetophenone, benzophenone, acetophenone; hydroxy ketones such as (1-[4-(2-hydroxyethoxy)-phenyl]-2-hydroxy-2-methyl-1-propan-1-one) (Irgacure® 2959 from CIBA), 2,2-di-sec-butoxyacethophenone, 2,2-diethoxy-2-phenyl-acetophenone, 1-hydroxy-cyclohex
  • photoinitiators of in particular 2,4,6-trimethylbenzoyldiphenyl-phosphine oxide, 1-hydroxycyclohexyl phenyl ketone, 2,2-dimethoxy-1,2-diphenylethane-l-one [sic] and alkyl benzoyl ethers.
  • Cationic photo-initiator comprises notably compounds which are able to form aprotic acids or Bronsteäd acids upon exposure to activating light like UV or visible light.
  • suitable cationic photo-initiator without any limitations are listed below: aryldiazonium salts, diaryliodonium salts, triarylsulfonium salts, triarylselenium salts.
  • Organic peroxides can include, but are not limited to, peroxycarbonates, peroxyesters, dialkylperoxides, diacylperoxide, diperoxyketals, ketoneperoxides, hydroperoxides, benzoyl peroxide, cyclohexyl peroxydicarbonate and isopropyl peroxydicarbonate
  • thermal initiators can include, but are not limited to, ammoniumpersulfate, potassiumpersulfate, and sodiumpersulfate.
  • a co-initiator represents a molecule as part of a chemical system which does not absorb light but, nevertheless, participates in the production of the reactive species.
  • Co-initiator is particularly suitable in combination with some free-radical initiator, like benzophenone which requires a second molecule, such as an amine, to produce a curable radical. Then, under UV radiation, benzophenone reacts with a tertiary amine by hydrogen abstraction, to generate an alpha-amino radical which is well known to initiate polymerization of (meth)acrylate monomer(s) and/or oligomer(s)
  • co-initiators examples include reactive amine co-initiators commercially available from Sartomer company under the trade names of CN-381, CN6383, CN-384, and CN-386, where these co-initiators are monoacrylic amines, diacrylic amines, or mixture thereof.
  • co-initiators include triethylamine, N-methyldiethanloamine, triethanolamine, ethyl-4-simethylaminobenzoate, ethyl-2-dimethylaminobenzoate, n-butoxyethyl-4-dimethylamino benzoate-p-dimethyl amino benzaldehyde, N,N-dimethyl-p-toluidine, and octyl-p-(dimethylamino)benzoate.
  • advantageous monomers or oligomer (A) are such presented reactive groups selected from epoxy and (meth)acrylate.
  • polymerizable composition comprising at least a monomer (B) which is able to expand after polymerization and at least a monomer or oligomer (A) which is able to present a low shrinkage.
  • some chemical modification could be introduced to the chemical structure of such monomer or oligomer (A) as, for example, an increased chain length, a low number of double bonds, or a reduced number of reactive groups like no more than three.
  • monomer or oligomer (A), as described herein, are generally selected for having the lowest possible functionality (number of reactive groups), the highest possible molecular weight (e.g., increased pendant group size); and a low Tg.
  • the monomer (or oligomer) (A) While many conventional monomers or oligomers typically undergo a volume shrinkage of about greater than about 5%, with an average volume shrinkage of about 10%, or in a range of greater than about 5% to up to about 14%, the monomer (or oligomer) (A) will exhibit a volume shrinkage of about 5% or less.
  • the low shrinkage monomer (or oligomer) (A) by virtue of the characteristics described, are known to exhibit a reduced shrinkage as compared with a conventional monomer that does not have one of the characteristics just described.
  • Examples of such specific monomer (A) include, but are not limited to, a diacrylate monomer (e.g., 1,4′-bis ⁇ 4-[6-(acryloyl)-1-hexyloxy] benzoyloxy ⁇ 2-t-butylbenzene; a dimethacrylate monomer (e.g., 1,4′-bis ⁇ 4-[6-(methacryloyl)-1-hexyloxy]benzoyloxy ⁇ 2-t-butylbenzene, 4,4′-bis ⁇ 4-[6-(methacryloyloxy)hexyloxy]benzoyloxy ⁇ diphenylether (DPEHDMA); and 2-(t-butyl)-1,4-bis-[4-(6-methacryloxy-hexan-1-oxy)-benzoyloxy]-benzen.
  • a monomer (or oligomer) (A) may also be one that has a methacrylate side group rather than an acrylate side
  • solvents suitable for the polymerizable composition are organic solvents, preferentially polar solvent like methanol, ethanol, propanol, butanol, glycols, and glycol monoethers. This solvent could be used alone or in combination. Used of solvent may be particularly relevant to adjust the viscosity of monomer component (A) and (B), more particularly when said composition will be processed through an additive manufacturing process, and more particularly through a jetting process.
  • an object of the invention is also a method of manufacturing an ophthalmic lens from a polymer composition in accordance with the invention, by a casting process or by an additive manufacturing process.
  • Such casting process and equipment required are for example well described in the document U.S. Pat. No. 5,662,839.
  • a method of manufacturing an ophthalmic lens from a polymerizable composition in which a mold is assembled comprising two molding shells and an annular closure member disposed around said molding shells and defining therewith a required molding cavity, said mold is filled with polymerizable composition, and polymerization of said polymerizable composition is as least started, in which method the operations of assembling said mold, filling it and at least starting polymerization of said polymerizable composition are conducted in the same device.
  • the polymerization may be initiated by thermal polymerization or by actinic polymerization depending the nature of monomer or oligomer (A) and monomer (B) comprised to the polymerizable composition and the associated initiators used.
  • the polymer composition of the present invention is advantageously processed through an additive manufacturing process.
  • this method to manufacturing an ophthalmic lens presents the advantage to combine the best optimization of the present invention: shrinkage control, less consumption of polymer composition, and ability to obtain directly a ophthalmic lens directly adapted or closely adapted to the prescription of a wearer and/or shape of frame choice by said wearer.
  • the invention proposes a method of manufacturing an ophthalmic lens wherein the polymerizable composition of the invention, is manufactured by an additive manufacturing process comprising the following steps:
  • a first treatment increases the viscosity of the voxels such that they substantially remain where deposited and have sufficient cohesion to support later-deposited voxels.
  • a second voxel or group of voxels
  • monomer(s) and/or oligomer from the first voxel (or group of voxels) diffuse into the second voxel (or group of voxels) either spontaneously or under application of a second treatment.
  • the second treatment can optionally polymerize or increase the viscosity of the resulting combination of voxels.
  • polymerizable compositions may be curable by differing means, such as differing intensity, dosage, rate, and/or frequency of light, and or by the presence of different initiating agents.
  • said three mains actions may be achieved voxel-to-voxel, line-to-line, layer-by-layer, and/or after all desired layers have been formed to produce the ophthalmic lens.
  • Constituting voxels will include at least one of the following: 1) depositing a voxel as a droplet of polymerizable composition to a substrate, through an inkjet head of an ink-jet printer; in this case the additive manufacturing technology used is polymer jetting; depositing a voxel as performing selective partial polymerization of a polymerizable composition in a thin layer on a substrate; in this case the additive manufacturing technology used is stereolithography [stereolithography, mask stereolithography or mask projection stereolithography].
  • crosslinking process which could be initiate by cationic reaction, by free radical reaction or by condensation reaction by applying activating light or thermal treatment to polymerizable composition;
  • each step of increasing viscosity in a method may be identical or different.
  • viscosity refers to a fluid's resistance to deformation.
  • Polymerizable composition suitable for use in an additive manufacturing device, in accordance with the invention, typically presents a viscosity comprised from 40 to 100 cPs at 25° C.
  • the step of increasing viscosity is able to increase the initial viscosity of the polymerizable composition from 5 times to 20 times, the final viscosity of the ophthalmic lens manufactured by said method being more than 50 000 cPs at 25° C.
  • Inter-diffusing step(s) can be promoted by processes selected from:
  • Exposure to radiation may be realized for example, through heating, heated convection, infra-red heating, microwave.
  • each step of inter-diffusing is identical or different.
  • Post-treatment step(s) may be selected from:
  • each step of post-treatment is identical or different.
  • each polymerizable composition comprises at least a monomer/oligomer (A) and a monomer (B), but said monomer/oligomer (A) may be different in each polymerizable composition like a monomer/oligomer (A1) and (A2), and/or monomer (B) may be different in each polymerizable composition like a monomer (B1) and a monomer (B2).
  • Such polymer composition obtained by a polymerizable composition comprising for example an alternative deposition of a voxel of polymerizable composition comprising monomer (A1) and monomer (B1) and a voxel of polymerizable composition comprising monomer (A2) and monomer (B2), may advantageously presented optimize properties as refractive index or mechanical properties.
  • voxels comprise different polymerizable compositions such that some voxels comprise a first polymerizable composition comprising monomer or oligomer (A) and monomer (B), and some other voxels comprise a different polymerizable composition comprising a monomer or oligomer (A′) and monomer (B′), (A′) being chemically different than (A), and (B′) being chemically different than (B).
  • Opt lens is defined as lens adapted namely for mounting in eyeglasses whose function is to protect the eye and/or to correct vision; this lens is selected from the afocal, unifocal, bifocal, trifocal, and progressive lens. Then it is understood that ophthalmic lens may be corrective or un-corrective.
  • Eyeglasses wherein ophthalmic lens will be mounted could be either traditional frame comprising two distinctive ophthalmic lenses, one for the right eye and one for the left eye, or like mask, visor, helmet sight or goggle, wherein one ophthalmic lens facing simultaneously the right and the left eyes.
  • Ophthalmic lens manufactures by a method of the invention may be produces with traditional geometry as a circle or may be produced to be fitted to the frame intended.
  • the present invention presents a great advantage to manufacture directly a three-dimensional ophthalmic lens in accordance with the geometry of the frame for which said ophthalmic lens is dedicated.
  • Ophthalmic lens manufacture in accordance with a method of the invention can furthermore be functionalized, in a further step after optionally post-treatment step, by adding at least a functional coating and/or a functional film.
  • Functionalities may be added on one face of the ophthalmic lens, or on the two faces of ophthalmic lens, and on each faces, functionalities may be identical or different.
  • a functionality selected from anti-impact, anti-abrasion, anti-soiling, anti-static, anti-reflective, anti-fog, anti-rain, self-healing, polarization, tint, photochromic, selective wavelength filter which could be obtain through an absorption filter or reflective filter.
  • Such selective wavelength filters are particularly interested to filter ultra-violet radiation, blue light radiation, or infra-red radiation for example.
  • the functionality may be added by at least one process selected from dip-coating, spin-coating, spray-coating, vacuum deposition, transfer process or lamination process.
  • transfer process it is understood that functionality is firstly deposited on a support like a carrier, and then is transferred from said carrier to said ophthalmic lens through an adhesive layer deposited between the two elements.
  • Lamination is defined as obtaining a permanent contact between a film which comprises at least one functionality as mentioned hereinbefore and the surface of the ophthalmic lens to be treated, said permanent contact being obtained by the establishment of a contact between said film and said lens, followed optionally by a polymerization step or a heating step, in order to finalize the adhesion and adherence between the two entities.
  • the assembled film and the optical lens form one single entity.
  • glue is present in the interface of the film and the ophthalmic lens.
  • Ophthalmic lens manufacture by a method of the present invention should present the following characteristics: a high transparency with an absence of or optionally a very low light scattering or haze, a high Abbe number of greater than or equal to 30 and preferably of greater than or equal to 35, in order to avoid chromatic aberrations, a low yellowing index and an absence of yellowing over time, a good impact strength (in particular according to the CEN and FDA standards), a good suitability for various treatments (shock-proof primer, anti-reflective or hard coating deposition, and the like) and in particular good suitability for colouring, a glass transition temperature value preferably of greater than or equal to 65° C. and better still of greater than 90° C.
  • Haze is the percentage of transmitted light that, in passing through specimen, deviates from the incident beam by forward scattering. Only light flux deviating more than 2.5° on the average is considered to be haze.
  • Haze is a measure of intensity of the transmitted light that is scattered more than 2.5°. It appears as a milky, smoky, hazy field when looking through a packaging material. Low values are a measurement of low “haze”. As haze increases, loss of contrast occurs until the object cannot be seen. Usually an ophthalmic lens could present a haze level less than 1.
  • a polymerizable composition comprised: 3,9-dimethylene-1,5,7,11-tetraoxaspiro[5.5]undecane, (DMSOC) (a free radically polymerizable expanding monomer as monomer (B)) added to compensate for shrinkage of the other curable components; 2,2 bis[p-(2′-hydroxy-3-methacryloxypropoxyphenyl)] propane, (bis-GMA(A)), which is the base resin for the optical part to be manufactured; Triethyleneglycol dimethacrylate (TEGDMA), added as a low viscosity reactive diluent; N,N′-dimethyl-p-toluidine used as a free radical accelerator (promoter); and dicumyl peroxide is used to cure the epoxy and as the free radical catalyst (photoinitiator) to polymerize the DMSOC and other acrylates, as described in Table 1 below.
  • This formulation when blended and cured versus a control not containing the expanding mono
  • a polymerizable composition comprises: at least a first quantity of 3,9-dimethylene-1,5,7,11-tetraoxaspiro[5.5]undecane (DMSOC), (known to expand 4.3% at room temperature and 7% at a temperature just below its melting point of 70° C.) as the expanding monomer (B); to which is added diethyleneglycol bis allylcarbonate (A), which is the base resin for the manufacture of the optical part and (known to copolymerize with DMSOC); dicumyl peroxide, as a free radical photoinitiator used for curing; and N,N′-dimethyl-p-toluidine as a free radical accelerator, used to reduce the time and energy needed to reach maximum cure, as described in Table 2 below.
  • DMSOC 3,9-dimethylene-1,5,7,11-tetraoxaspiro[5.5]undecane
  • voxels are partially polymerized with or without induced diffusion, such as by thermal diffusion; after which free radical polymerization is induced and viscosity is unchanged versus that of the control not containing the expanding monomer which exhibits approximately 14% shrinkage.
  • the resulting 3D polymer exhibits good optics and geometry.
  • a polymerizable composition included: a first quantity of the bi-cyclic monomer, 3,9-di(5-norbornene-2,2)-1,5,7,11-tetraoxaspiro(5,5)undecane, (NSOC), a white crystalline solid expanding monomer (B), with addition of Diglycidyl ether of bisphenol A epoxy (UVR-6110 from Dow Chemical) (A1); and with the addition of Bis (3, 4-Epoxycyclohexylmethyl) adipate (UVR-6128 from Dow Chemical)(A2) as the low shrinkage base monomers for the optical part, with Omicure BC-120 (Boron trifluoride adduct) and Omicure DDA-5 (Dicyandiamide) as curing agents, as described in Table 3 below.
  • UVR-6110 from Dow Chemical
  • A2 Diglycidyl ether of bisphenol A epoxy
  • Bis (3, 4-Epoxycyclohexylmethyl) adipate UVR-6128 from
  • a polymerizable composition included: 3,4-Diepoxycylcohexane, the base resin for the optical part to be manufactured (A1); 5 mol % the expanding monomer Tetraspiroorthocarbonate, (TETRASOC)(B); 2 mol % of Triarylsulfoniumhexafluoroantimonate, a cationic photoinitiator to photo-cure the epoxy; with Cyclohexanol, 4,4′-(1-methylethylidene)bis-, polymer with (chloromethyl)oxirane (Eppaloy 5001) (A2), the second part of the base resin; as described in Table 4 below, the co-polymer exhibited no shrinkage upon polymerization and therefore, the epoxy retained most of its typical mechanical properties.
  • TTRASOC Tetraspiroorthocarbonate
  • Triarylsulfoniumhexafluoroantimonate a cationic photoinitiator to photo-cure the
  • the present invention is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein.

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  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
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  • General Physics & Mathematics (AREA)
  • Polymerisation Methods In General (AREA)
US15/106,617 2013-12-20 2013-12-20 Polymer Composition and Methods Using Said Polymer Composition to Manufacture Ophthalmic Lens Abandoned US20170031059A1 (en)

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US10744729B2 (en) 2016-12-12 2020-08-18 Luxexcel Holding B.V. Identification system for optical components
CN111830733A (zh) * 2020-07-22 2020-10-27 浙江伟星光学有限公司 一种环氧树脂制备涂层的变色眼镜片
US20210009750A1 (en) * 2018-03-22 2021-01-14 Tissium Sa 3d printing composition for biomaterials
IT202100013421A1 (it) * 2021-05-24 2022-11-24 Fondazione St Italiano Tecnologia Formulazioni di fotoresist per tecniche di microstampa 3D
US11591494B2 (en) 2019-03-18 2023-02-28 Hewlett-Packard Development Company, L.P. Three-dimensional printing with epoxy and amine compounds
US12350879B2 (en) 2020-05-06 2025-07-08 Eaton Intelligent Power Limited Method of additively manufacturing transparent lenses for luminaries

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EP3473418B1 (fr) * 2017-10-19 2023-12-06 Essilor International Procédé de fabrication d'une lentille ophtalmique
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EP3871866B1 (fr) * 2020-02-28 2023-06-21 Essilor International Composition de revêtement d'apprêt de polarisation de lentille ophtalmique

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Publication number Priority date Publication date Assignee Title
US10744729B2 (en) 2016-12-12 2020-08-18 Luxexcel Holding B.V. Identification system for optical components
US20210009750A1 (en) * 2018-03-22 2021-01-14 Tissium Sa 3d printing composition for biomaterials
US11591494B2 (en) 2019-03-18 2023-02-28 Hewlett-Packard Development Company, L.P. Three-dimensional printing with epoxy and amine compounds
US11787110B2 (en) 2019-03-18 2023-10-17 Hewlett-Packard Development Company, L.P. Three-dimensional printing with epoxy and amine compounds
US12350879B2 (en) 2020-05-06 2025-07-08 Eaton Intelligent Power Limited Method of additively manufacturing transparent lenses for luminaries
CN111830733A (zh) * 2020-07-22 2020-10-27 浙江伟星光学有限公司 一种环氧树脂制备涂层的变色眼镜片
IT202100013421A1 (it) * 2021-05-24 2022-11-24 Fondazione St Italiano Tecnologia Formulazioni di fotoresist per tecniche di microstampa 3D
WO2022249002A1 (fr) * 2021-05-24 2022-12-01 Fondazione Istituto Italiano Di Tecnologia Techniques de micro-impression 3d de formulations de photoresists
US12429766B2 (en) 2021-05-24 2025-09-30 Fondazione Istituto Italiano Di Tecnologia Photoresist formulations 3D microprinting techniques

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BR112016014351A2 (pt) 2017-08-08
CA2934674A1 (fr) 2015-06-25
EP3084484B1 (fr) 2018-03-21
ES2673569T3 (es) 2018-06-22
CN105829922B (zh) 2019-10-25
US20210072425A1 (en) 2021-03-11
KR102219580B1 (ko) 2021-02-25
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AU2013408697A1 (en) 2016-07-07

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