US2005085617A1PendingUtilityA1

Polyurea/urethane optical material and method for making it

41
Assignee: YOUNGER MFG CO DBA YOUNGER OPTPriority: Feb 24, 2003Filed: Nov 11, 2004Published: Apr 21, 2005
Est. expiryFeb 24, 2023(expired)· nominal 20-yr term from priority
Inventors:Edwin C. SlagelMichael Slagel
C08G 18/4277C08G 18/12C08G 18/4202G02B 1/041
41
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Claims

Abstract

A polyurea/urethane material and method for making it provides for improved optical parts. The material allows for ease of manufacture of parts having good optical properties, high hardness, low density, and good impact resistance. The method provides for related manufacturing advantages.

Claims

exact text as granted — not AI-modified
1 - 46 . (canceled)  
     
     
         47 . An optical-quality, impact resistant part comprising a material produced by a method for making an optical-quality, impact resistant polyurea/urethane material, including: 
 reacting a first diisocyanate with a first polyol to form a urethane prepolymer having an equivalent ratio of at least about 3 isocyanate groups per hydroxyl group;    reacting a second diisocyanate with a second polyol to form a hydroxyl-terminated extended chain polymer having an equivalent ratio of between about 3 and about 8 hydroxyl groups per isocyanate group;    blending the hydroxyl-terminated extended chain polymer with a diamine to form a curing agent mixture; and    reacting the urethane prepolymer with the curing agent mixture and a catalyst, wherein the catalyst is configured to promote the reaction of the hydroxyl groups of the curing agent mixture with the isocyanate groups of the urethane prepolymer, to form the polyurea/urethane material.    
     
     
         48 . An optical-quality part comprising a material produced by a method for making an optical-quality, impact resistant polyurea/urethane material, including: 
 reacting a first diisocyanate with a first polyol to form a urethane prepolymer having an equivalent ratio of at least about 3 isocyanate groups per hydroxyl group;    reacting a second diisocyanate with a second polyol to form a hydroxyl-terminated extended chain polymer having an equivalent ratio of between about 3 and about 8 hydroxyl groups per isocyanate group;    blending the hydroxyl-terminated extended chain polymer with a diamine and a catalyst to form a curing agent mixture, wherein the catalyst is configured to promote the reaction of the hydroxyl groups of the curing agent mixture with the isocyanate groups of the urethane prepolymer; and    reacting the urethane prepolymer with the curing agent mixture to form the polyurea/urethane material.    
     
     
         49 . (canceled)  
     
     
         50 . The optical-quality, impact resistant part according to  claim 47 , wherein the urethane prepolymer has an equivalent ratio of between about 5 and about 16 isocyanate groups per hydroxyl group.  
     
     
         51 . The optical-quality, impact resistant part according to  claim 50 , wherein the urethane prepolymer has an equivalent ratio of between about 8 and about 12 isocyanate groups per hydroxyl group.  
     
     
         52 . The optical-quality, impact resistant part according to  claim 50 , wherein the hydroxyl-terminated extended chain polymer has an equivalent ratio of between about 3 and about 5 hydroxyl groups per isocyanate group  
     
     
         53 . The optical-quality, impact resistant part according to  claim 47 , wherein the first diisocyanate comprises an aliphatic or cycloaliphatic diisocyanate.  
     
     
         54 . The optical-quality, impact resistant part according to  claim 53 , wherein the aliphatic or cycloaliphatic diisocyanate comprises 4,4′-methylenebis(cyclohexyl isocyanate), 1,3-,1,4 bis(isocyanatomethyl)cyclohexane, isophorone diisocyanate, tetramethylxylene diisocyanate, or mixtures thereof.  
     
     
         55 . The optical-quality, impact resistant part according to  claim 47 , wherein the first polyol comprises a diol having a molecular weight between about 150 and about 4,000.  
     
     
         56 . The optical-quality, impact resistant part according to  claim 55 , wherein the diol comprises polyester diol, polyether diol, caprolactone diol, polycarbonate diol, or mixtures thereof.  
     
     
         57 . The optical-quality, impact resistant part according to  claim 47 , further comprising a step of blending additives into the urethane prepolymer.  
     
     
         58 . The optical-quality, impact resistant part according to  claim 47 , wherein the second diisocyanate comprises an aliphatic or cycloaliphatic diisocyanate.  
     
     
         59 . The optical-quality, impact resistant part according to  claim 58 , wherein the aliphatic or cycloaliphatic diisocyanate comprises 4,4′-methylenebis(cyclohexyl isocyanate), 1,3-,1,4-bis(isocyanatomethyl)cyclohexane, or mixtures thereof.  
     
     
         60 . The optical-quality, impact resistant part according to  claim 47 , wherein the second polyol comprises a diol having a molecular weight between about 90 and about 4,000.  
     
     
         61 . The optical-quality, impact resistant part according to  claim 60 , wherein the second polyol comprises one or more caprolactone diols.  
     
     
         62 . The optical-quality, impact resistant part according to  claim 47 , wherein the diamine comprises aromatic diamine.  
     
     
         63 . The optical-quality, impact resistant part according to  claim 62 , wherein the aromatic diamine comprises diethyltoluene-diamine, 4,4′-methylenebis(3-chloro-2,6-diethylaniline), 4,4-methylene-bis(2-chloro-aniline), 1,2-bis (2-aminophenylthio)ethane, or mixtures thereof.  
     
     
         64 . The optical-quality, impact resistant part according to  claim 47 , wherein the catalyst is present in an amount between about 10 ppm and about 650 ppm of the combined amount of the urethane prepolymer and the curing agent mixture.  
     
     
         65 . The optical-quality, impact resistant part according to  claim 47 , wherein the step of reacting the urethane prepolymer with the curing agent mixture in the presence of a catalyst comprises blending the catalyst into the curing agent mixture.  
     
     
         66 . The optical-quality, impact resistant part according to  claim 47 , wherein the catalyst comprises metal.  
     
     
         67 . The optical-quality, impact resistant part according to  claim 66 , wherein the metal is tin, cobalt, or mercury.  
     
     
         68 . The optical-quality, impact resistant part according to  claim 67 , wherein the catalyst comprises dibutyl tin dilaurate, dibutyl tin diacetate, dibutyl tin oxide, dimethyl tin carboxylate, or mixtures thereof.  
     
     
         69 . The optical-quality, impact resistant part according to  claim 47 , wherein the steps of reacting a first diisocyanate with a first polyol, reacting a second diisocyanate with a second polyol, and blending the hydroxyl-terminated extended chain polymer with a diamine all are performed while minimizing contact of the first diisocyanate, first polyol, second diisocyanate, second polyol, hydroxyl-terminated extended chain polymer, or diamine with oxygen or water.  
     
     
         70 . The optical-quality, impact resistant part according to  claim 47 , wherein the step of reacting the urethane prepolymer with the curing agent mixture comprises reacting the urethane prepolymer with the curing agent mixture in a ratio ranging between about 0.85 to about 1.1 amine units per isocyanate unit.  
     
     
         71 . The optical-quality, impact resistant part according to  claim 70 , wherein the urethane prepolymer and the curing agent mixture are reacted in a ratio ranging between about 0.90 to about 1.0 amine units per isocyanate unit.  
     
     
         72 . The optical-quality, impact resistant part according to  claim 47 , further comprising a solid insert.  
     
     
         73 . The optical-quality, impact resistant part according to  claim 47 , further comprising a film.  
     
     
         74 . The optical-quality, impact resistant part according to  claim 47 , further comprising a laminate.  
     
     
         75 . The optical-quality part according to  claim 48 , wherein the urethane prepolymer has an equivalent ratio of between about 5 and about 16 isocyanate groups per hydroxyl group.  
     
     
         76 . The optical-quality part according to  claim 75 , wherein the urethane prepolymer has an equivalent ratio of between about 8 and about 12 isocyanate groups per hydroxyl group.  
     
     
         77 . The optical-quality part according to  claim 48 , wherein the hydroxyl-terminated extended chain polymer has an equivalent ratio of between about 3 and about 5 hydroxyl groups per isocyanate group.  
     
     
         78 . The optical-quality part according to  claim 48 , wherein the first diisocyanate comprises an aliphatic or cycloaliphatic diisocyanate.  
     
     
         79 . The optical-quality part according to  claim 78 , wherein the aliphatic or cycloaliphatic diisocyanate comprises 4,4′-methylenebis(cyclohexyl isocyanate), 1,3-1,4 bis(isocyanatomethyl)cyclohexane, isophorone diisocyanate, tetramethylxylene diisocyanate, or mixtures thereof.  
     
     
         80 . The optical-quality part according to  claim 48 , wherein the first polyol comprises a diol having a molecular weight between about 150 and about 4,000.  
     
     
         81 . The optical-quality part according to  claim 80 , wherein the diol comprises polyester diol, polyether diol, caprolactone diol, polycarbonate diol, or mixtures thereof.  
     
     
         82 . The optical-quality part according to  claim 48 , further comprising a step of blending additives into the urethane prepolymer.  
     
     
         83 . The optical-quality part according to  claim 48 , wherein the second diisocyanate comprises an aliphatic or cycloaliphatic diisocyanate.  
     
     
         84 . The optical-quality part according to  claim 83 , wherein the aliphatic or cycloaliphatic diisocyanate comprises 4,4′-methylenebis(cyclohexyl isocyanate), 1,3-1,4-bis(isocyanatomethyl)cyclohexane, or mixtures thereof.  
     
     
         85 . The optical-quality part according to  claim 48 , wherein the second polyol comprises a diol having a molecular weight between about 90 and about 4,000.  
     
     
         86 . The optical-quality part according to  claim 85 , wherein the second polyol comprises one or more caprolactone diols.  
     
     
         87 . The optical-quality part according to  claim 48 , wherein the diamine comprises aromatic diamine.  
     
     
         88 . The optical-quality part according to  claim 87 , wherein the aromatic diamine comprises diethyltoluene-diamine, 4,4′-methylenebis(3-chloro-2,6-diethylaniline), 4,4-methylene-bis(2-chloro-aniline), 1,2-bis(2-aminophenylthio)ethane, or mixtures thereof.  
     
     
         89 . The optical-quality part according to  claim 48 , wherein the catalyst is present in an amount between about 10 ppm and about 650 ppm of the combined amount of the urethane prepolymer and the curing agent mixture.  
     
     
         90 . The optical-quality part according to  claim 48 , wherein the catalyst comprises metal.  
     
     
         91 . The optical-quality part according to  claim 90 , wherein the metal is tin, cobalt, or mercury.  
     
     
         92 . The optical-quality part according to  claim 91 , wherein the catalyst comprises dibutyl tin dilaurate, dibutyl tin diacetate, dibutyl tin oxide, dimethyl tin carboxylate, or mixtures thereof.  
     
     
         93 . The optical-quality part according to  claim 48 , wherein the steps of reacting a first diisocyanate with a first polyol, reacting a second diisocyanate with a second polyol, and blending the hydroxyl-terminated extended chain polymer with a diamine all are performed while minimizing contact of the first diisocyanate, first polyol, second diisocyanate, second polyol, hydroxyl-terminated extended chain polymer, or diamine with oxygen or water.  
     
     
         94 . The optical-quality part according to  claim 48 , wherein the step of reacting the urethane prepolymer with the curing agent mixture comprises reacting the urethane prepolymer with the curing agent mixture in a ratio ranging between about 0.85 to about 1.1 amine units per isocyanate unit.  
     
     
         95 . The optical-quality part according to  claim 94 , wherein the urethane prepolymer and the curing agent mixture are reacted in a ratio ranging between about 0.90 to about 1.0 amine units per isocyanate unit.  
     
     
         96 . The optical-quality part according to  claim 48 , further comprising a solid insert.  
     
     
         97 . The optical-quality part according to  claim 48 , further comprising a film.  
     
     
         98 . The optical-quality part according to  claim 48 , further comprising a laminate.

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