Glyoxal adhesive system and process for manufacturing the same

Patent metadata

Field	Value
Publication number	US-2015225616-A1
Application number	US-201314418666-A
Country	US
Kind code	A1
Filing date	Aug 1, 2013
Priority date	Aug 1, 2012
Publication date	Aug 13, 2015
Grant date	—

Abstract

An optical adhesive product and a process for manufacturing an optical adhesive product, laminated film ensembles, and laminated lenses. The optical adhesive product includes a glyoxal water solution that is pH adjusted for use as an optical adhesive that demonstrates a wet peel force strength above about 6 Newtons. A water based polymer, such as PVOH, may be added to the adhesive system. According to the process, the glyoxal adhesive system is manufactured and utilized to laminate TAC-PVA-TAC films together to form a polar film ensemble. The polar film ensemble is laminated to an optical substrate and in the case of an ophthalmic lens, surfaced, coated and edged. The optical adhesive product avoids film separation in the polar TAC-PAV-TAC film ensemble during edging.

First claim

1 . An optical adhesive product for improved wet adhesion in laminated opthalmic lenses comprising:
a glyoxal water solution, said glyoxal water solution containing between about 5% and about 50% by weight glyoxal, said glyoxal water solution being adjusted to a pH below about 7,
wherein the optical adhesive product comprises an adhesive for laminated ophthalmic lens that demonstrates a wet peel force strength above about 6 Newtons.

2 . The product of claim 1 , wherein the glyoxal water solution consists of:
glyoxal present in an amount between 30% and 50% by weight; less than 1% by weight of a pH adjusting compound; and the remainder water,
wherein the optical adhesive product is devoid of other compounds and demonstrates a wet peel force strength between about 8 to about 12 Newtons.

3 . The product of claim 2 , wherein said pH adjusting compound comprises hydrochloric acid (HCl) and the optical adhesive product is adjusted to a pH below about 6.

4 . The product of claim 1 further comprising:
a water based polymer that is present in an amount less than or equal to the amount of glyoxal.

5 . The product of claim 4 , wherein the optical adhesive product comprises:
glyoxal present in an amount between about 3% and 40% by weight; said water based polymer comprising polyvinyl alcohol (PVOH) polymer present in an amount between 2% and 6% by weight; less than 1% by weight of a pH adjusting compound; and the remainder water,
wherein the optical adhesive product demonstrates a wet peel force strength between about 6 to about 18 Newtons.

6 . The product of claim 5 , wherein said glyoxal is present in an amount of about 5%-10% by weight and said PVOH is present in an amount of about 3%-4% by weight, wherein the optical adhesive product demonstrates a wet peel force strength between about 10 to about 16 Newtons.

7 . The product of claim 4 , wherein the water based polymer is selected from the group consisting of water based polymers containing OH groups in the structure, polyurethanes (PU) containing hydroxy groups, hydroxyethyl cellulose, hydroxypropyl cellulose, sodium carboxymethyl cellulose, and agarose.

8 . A process for manufacturing an optical adhesive product for improved wet adhesion in laminated opthalmic lenses comprising the steps of:
providing a glyoxal water solution containing between about 3% and about 40% by weight glyoxal; and adding an acid for adjusting the pH of said glyoxal water solution to below about 6 to form the optical adhesive product that demonstrates a wet peel force strength above about 6 Newtons.

9 . The process of claim 8 , wherein said adding step includes adding a water based polymer in an amount less than the glyoxal water solution.

10 . The process of claim 9 , wherein the optical adhesive product includes:
glyoxal present in an amount between about 3% and 40% by weight; said water based polymer comprising polyvinyl alcohol (PVOH) polymer present in an amount between 2% and 4% by weight; less than 1% by weight of the acid; and the remainder water,
wherein the optical adhesive product demonstrates a wet peel force strength between about 6 to about 18 Newtons.

11 . The process of claim 10 , wherein said glyoxal is present in an amount of about 5%-10% by weight and said PVOH is present in an amount of about 3%-4% by weight, wherein the optical adhesive product demonstrates a wet peel force strength between about 10 to about 16 Newtons.

12 . The process of claim 10 , wherein the water based polymer is selected from the group consisting of water based polymers containing OH groups in the structure, polyurethanes (PU) containing hydroxy groups, hydroxyethyl cellulose, hydroxypropyl cellulose, sodium carboxymethyl cellulose, and agarose.

13 . The process of claim 10 , wherein the acid is hydrochloric acid (HCl).

14 . The process of claim 8 , wherein following said adding step the process further includes:
providing optical films; introducing the optical adhesive product between the films; and laminating the optical films together.

15 . The process of claim 14 , wherein said providing optical films step includes providing two triacetate cellulose (TAC) films and a caustic treated polarized polyvinyl alcohol (PVA) film, wherein the PVA film is laminated in between the two TAC films.

16 . The process of claim 15 , wherein said laminating step comprises roller laminating the films together in an environment between about 50 and 110 degrees Celsius for between about 0.1 and 3 hours to produce a polar TAC-PVA-TAC film ensemble having good polarization, color and cosmetics, wherein the optical adhesive product is present in uniformly thin layers, each less than about 5 microns.

17 . The process of claim 16 , wherein following said laminating step, the process includes the step of further laminating the polar TAC-PVA-TAC film ensemble to an optical substrate with an adhesive system selected from the group consisting of a single layer adhesive system, a bi-layer adhesive system and a tri-layer adhesive system to form a laminated substrate.

18 . The process of claim 17 , wherein following said further laminating step, the process includes the further steps of:
surfacing the substrate which comprises a semi-finished (SF) ophthalmic lens; coating the surfaced lens; and edging the coated lens, wherein the optical adhesive product avoids film separation in the polar TAC-PAV-TAC film ensemble during edging.

19 . The process of claim 18 , wherein the ophthalmic lens is made from polyepisulfide material having an index of refraction of 1.74 and the coating step includes coating the surfaced lens with a coating selected from the group consisting of protective coating, hard coating, anti-reflective coating, photochromic coatins, tinted coating, anti-fog coating, and anti-smudge coating.

20 . The process of claim 17 , wherein the resulting laminated substrate includes an optical stack having the following layers in order, a polyepisulfide lens, an adhesive system, TAC film, the optical adhesive product, PVA film, the optical adhesive product, TAC film and a coating.

21 . An optical article comprising the following layers in order:
an optical substrate, preferably an ophthalmic lens; an adhesive system; a TAC film; an optical adhesive product according to claim 1 ; a PVA film; an optical adhesive product; a TAC film; and a coating.

22 . The article of claim 21 , wherein the optical substrate is a polyepisulfide ophthalmic lens.

Assignees

• Essilor Int

Inventors

• Jiang Peiqi
• Berzon Ronald A
• Weber Steven

Classifications

• B32B27/306

  comprising vinyl acetate or vinyl alcohol (co)polymers · CPC title

• C09J101/28

  Alkyl ethers · CPC title

• C09J129/04 Primary

  Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids · CPC title

• B32B2329/04

  Polyvinylalcohol · CPC title

• C09J175/04

  Polyurethanes · CPC title