Curable composition and cured product from same

Patent metadata

Field	Value
Publication number	US-10988568-B2
Application number	US-201615748037-A
Country	US
Kind code	B2
Filing date	Aug 3, 2016
Priority date	Aug 13, 2015
Publication date	Apr 27, 2021
Grant date	Apr 27, 2021

Abstract

Provided is a curable composition which has chargeability into silicone molds and curability at excellent levels, less causes the silicone molds to swell, and allows the silicone molds to have better durability and a longer service life in repeated use. The curable composition according to the present invention contains curable compounds and a cationic initiator and is used for production of an optical component by molding using silicone molds. The curable compounds include (A) a cycloaliphatic epoxy compound in a content of 10 weight percent or more of the totality of all the curable compounds contained in the curable composition. Of the totality of all the curable compounds contained in the curable composition, 10 to 50 weight percent is a curable compound or compounds having a molecular weight of 400 or more.

First claim

The invention claimed is:

1. A curable composition for production of an optical component by molding using silicone molds, the curable composition comprising:
curable compounds; and
a cationic initiator,
the curable compounds comprising
(A) a cycloaliphatic epoxy compound;
(B) an oxetane compound; and
(C) a glycidyl ether epoxy compound,
the cycloaliphatic epoxy compound (A) being a compound represented by Formula (a):

wherein R 1 to R 18 are each, identically or differently, selected from, hydrogen, halogen, a hydrocarbon group optionally containing oxygen or halogen, and optionally substituted alkoxy; and X is selected from a single bond and a linkage group,
wherein the linkage group is selected from divalent hydrocarbon groups, alkenylenes with part or all of carbon-carbon double bond(s) being epoxidized, carbonyl, ether bond, ester bond, amido, and groups each including two or more of these groups linked to each other,
wherein the cycloaliphatic epoxy compound (A) is present in a content of 10 weight percent or more of the totality of all the curable compounds contained in the curable composition,
wherein the glycidyl ether epoxy compound (C) comprises an aromatic glycidyl ether epoxy compound, and an alicyclic glycidyl ether epoxy compound,
wherein the cycloaliphatic epoxy compound (A), the oxetane compound (B), and the glycidyl ether epoxy compound (C) are present in combination in a total content of 90 weight percent or more of the totality of all the curable compounds contained in the curable composition, and
wherein of the totality of all the curable compounds contained in the curable composition, 10 to 50 weight percent are a curable compound or compounds having a molecular weight of 400 or more.

2. The curable composition according to claim 1 ,
wherein the oxetane compound (B) is present in a content of 10 to 60 weight percent of the totality of all the curable compounds contained in the curable composition, and
wherein the glycidyl ether epoxy compound (C) is present in a content of 20 to 80 weight percent of the totality of all the curable compounds contained in the curable composition.

3. The curable composition according to claim 1 ,
wherein
the cycloaliphatic epoxy compound (A) is present in a content of 10 to 50 weight percent of the totality of all the curable compounds contained in the curable composition,
the oxetane compound (B) is present in a content of 10 to 60 weight percent of the totality of all the curable compounds contained in the curable composition,
the glycidyl ether epoxy compound (C) is present in a content of 20 to 80 weight percent of the totality of all the curable compounds contained in the curable composition,
of the totality of all the curable compounds contained in the curable composition, 10 to 50 weight percent is a curable compound or compounds having a molecular weight of 600 to 900,
a content of a curable compound having a molecular weight of less than 200 is 30 weight percent or less of the totality of all the curable compounds contained in the curable composition, and
a content of a curable compound having a molecular weight of greater than 1000 is 30 weight percent or less of the totality of all the curable compounds contained in the curable composition.

4. The curable composition according to claim 1 ,
wherein the optical component is selected from a light diffusing lens, an imaging lens, and a sensor lens.

5. A cured product of the curable composition according to claim 1 .

6. An optical component comprising
the cured product according to claim 5 .

7. An optical device comprising
the optical component according to claim 6 .

8. A method for producing an optical component, the method comprising the steps of:
1) preparing molds comprising an upper mold and a lower mold, and charging the curable composition according to claim 1 into the lower mold;
2) assembling the upper mold with the lower mold charged with the curable composition;
3) applying at least one of light and heat and whereby curing the curable composition to give a cured product; and
4) demolding the cured product.

9. The method according to claim 8 for producing an optical component,
wherein the step 4 of demolding the cured product comprises the substeps in the sequence set forth:
a) removing one of the upper mold and the lower mold from the cured product;
b) securing the cured product to a support; and
c) removing the other mold from the cured product.

10. The method according to claim 9 for producing an optical component,
wherein the support is an adhesive film.

11. The method according to any one of claims 8 to 10 for producing an optical component,
wherein the step 1 further comprises, after charging the curable composition into the lower mold, degassing the charged curable composition.

12. The method according to claim 8 for producing an optical component,
wherein the step 4 further comprises dicing the demolded cured product.

13. The method according to claim 8 for producing an optical component,
wherein the molds are silicone molds.

14. The method according to claim 8 for producing an optical component,
wherein the molds are molds comprising an upper mold and a lower mold each having asperities in a surface to be in contact with the curable composition.

15. The method according to claim 8 for producing an optical component,
wherein the upper mold and the lower mold are individually secured to transparent supports.

16. The curable composition according to claim 1 ,
wherein the oxetane compound (B) is 3-ethyl-3-hydroxymethyloxetane, and
wherein the oxetane compound (B) is present in a content of 10 to 60 weight percent of the totality of all the curable compounds contained in the curable composition.

17. The curable composition according to claim 1 ,
wherein the cycloaliphatic epoxy compound (A) comprises one selected from 3,4-epoxycyclohexylmethyl (3,4-epoxy)cyclohexanecarboxylate and bis(3,4-epoxycyclohexylmethyl) ether.

18. The curable composition according to claim 1 ,
wherein the curable composition further comprises an ε-caprolactone-modified tetra(3,4-epoxycyclohexylmethyl) butanetetracarboxylate.

Assignees

• Daicel Corp

Inventors

• Fujikawa Takeshi
• Fukui Sadayuki

Classifications

• B29D11/00298

  Producing lens arrays · CPC title

• B29D11/00269

  Fresnel lenses · CPC title

• B29C33/405

  Elastomers, e.g. rubber (B29C33/50 takes precedence) · CPC title

• B29C2033/0005

  with transparent parts, e.g. permitting visual inspection of the interior of the cavity · CPC title

• B29C35/0888

  using transparant moulds · CPC title