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wl-hydrophilic-polymer/task2/task2-paper-info/US20220106497A1.json
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{
"protocol": "Free radical polymerization is utilized for synthesizing hydrophilic polymers. The coating composition involves a mixture comprising an initiator, a radical curable polyurethane with ethylenically unsaturated functional groups, and a liquid phase. The polyurethane is derived from the reaction products of a polyol component, a polyisocyanate component, an isocyanate-reactive surfactant, and an isocyanate-reactive component with ethylenically unsaturated functional groups. The curing process can be initiated through exposure to UV radiation, thermal radiation, or both, to impart desired anti-fog and wear resistance properties.1. Prepare a mixture comprising an initiator, a radical curable polyurethane with ethylenically unsaturated functional groups, and a liquid phase. 2. The polyurethane must include the reaction products of: A) a polyol component, B) a polyisocyanate component, C) an isocyanate-reactive surfactant, and D) an isocyanate-reactive component containing ethylenically unsaturated functional groups. 3. Utilize thermal or radiation-induced free radical polymerization to cure the coating composition, forming a hydrophilic polymeric polyurethane network. 4. Ensure the reactive surfactant binds to the network during the curing process. 5. Optionally, incorporate hydrophilic alkoxylated acrylate as part of the isocyanate-reactive component to enhance hydrophilicity and maintain permanent anti-fog properties. 6. Optionally, add metal oxide nanoparticles to improve abrasion resistance while ensuring optical transparency. 7. Apply the resulting coatings onto optically transparent substrates, such as lenses for eyeglasses.The coating compositions comprise an initiator, a radical curable polyurethane with ethylenically unsaturated functional groups, and a liquid phase. Suitable liquid phases include water, organic solvents, and combinations thereof. Select organic solvents based on the constituent components for polyurethane synthesis, ensuring they can dissolve the selected polyols and do not readily react with the polyisocyanates. Examples of suitable organic solvents include ketones (methylethylketone, methylisobutyl ketone, diacetone alcohol, 3,3-dimethyl-2-butanone, pentanedione), N-methyl pyrrolidone, acetonitrile, esters, glycol esters, and tertiary alcohols (tertiary-butyl alcohol, tertiary-amyl alcohol).The coating compositions of the present disclosure comprise an initiator selected from thermal radical initiators, photoinitiators, or a combination of both. Suitable thermal radical initiators include azo initiators like 2,2'-azobis(4-methoxy-2,4-dimethylvaleronitrile) and peroxide initiators such as benzoyl peroxide. Photoinitiators may include UV-sensitive compounds like benzoin or 2-hydroxy-2-methyl-1-phenyl-propan-1-one. The initiators are used in amounts ranging from 0.3 to 6 wt%, based on the total weight of the solid coating composition.The synthesis of hydrophilic polymers with functional groups involves the preparation of a radical curable polyurethane. This polyurethane is created through a reaction that includes the following components: (A) a polyol, (B) a polyisocyanate, (C) an isocyanate-reactive surfactant, and (D) an isocyanate-reactive component that possesses ethylenically unsaturated functional groups. The isocyanate-reactive component can be substituted with any compound having unsaturated reactive functionality, such as isocyanate-reactive alkenyl compounds that contain reactive vinyl, reactive acrylate, reactive methacrylate, or reactive allyl groups. The resulting radical curable polyurethane should be included in the final composition at a concentration ranging from 85 to 97.5 wt%, based on the total weight solids of the coating composition.The synthesis of hydrophilic polymers involves the use of polyols, specifically at least one polyol that is either a diol or a triol with main chain segments selected from polyethylene oxide, polypropylene oxide, or combinations thereof. Suitable diols can include polyethylene oxide side chain segments, alkyl diols, alkyl triols, polycarbonate diols, and polycarbonate triols. It is preferred to use a polypropylene oxide and polyethylene oxide block copolymer diol in an amount of approximately 10% to 25% polyethylene oxide by weight of the polyol. Similarly, for triols, a polypropylene oxide and polyethylene oxide copolymer triol with 60% to 95% polyethylene oxide is preferred. The polyols should have one or more hydrophilic regions due to the presence of the formula: —((CH2)nO-)m, where n is between 1 and 3, and m is between 1 and 10. The coating compositions should comprise one or more polyol in amounts ranging from 10-60 wt%, based on the total weight solids of the radical curable polyurethane.The synthesis involves using one or more multifunctional polyisocyanates, specifically diisocyanates or triisocyanates, to form polyurethane linkages. The components should be selected based on their isocyanate functionalities and include examples such as isophorone diisocyanate, hexamethylene diisocyanate, xylene diisocyanate, toluene diisocyanate, and diphenylmethane diisocyanate. For optimal light stability, aliphatic polyisocyanates such as IPDI-type and HDI-type diisocyanates are preferred. The coating compositions should consist of polyisocyanates in amounts ranging from 5.60 wt% to 58 wt%, which can vary across specified ranges based on the total weight solids of the radical curable polyurethane.The synthesis of hydrophilic polymers involves the following steps: 1. Use isocyanate-reactive surfactants containing reactive groups such as hydroxyl, thiol, or amine in amounts ranging from 1-50 wt % based on the total weight solids of the radical curable polyurethane. 2. Incorporate an isocyanate-reactive component with ethylenically unsaturated functional groups, adhering to the formula Y—R—X, where Y is an ethylenically unsaturated group and X is an isocyanate reactive group, in amounts ranging from 1-25 wt %. 3. Optionally include radical reactive surfactants containing groups like alkenyl, acrylate, or thiol at 0-20 wt %. 4. Combine these components with a polyol and a polyisocyanate to form the radical curable polyurethane, ensuring reactive functionalities from all components interact during the curing process. 5. Use multifunctional ethoxylated acrylate monomers to form the network. 6. Optionally add metal oxide particles to enhance properties, maintaining their concentrations between 0 and 70 wt %. 7. Apply the mixture to the desired substrate, followed by curing to form the final hydrophilic polymer.The coating compositions described can be applied to substrates using methods such as flow coating, spray coating, curtain coating, dip coating, spin coating, slot-die coating, roll coating, etc., to form a continuous surface film. The coated substrate is cured by exposing it to UV radiation, visible light radiation, or EB radiation, with cumulative UV radiation exposure needed for curing being between 1.5 to 3.0 J/cm² when using a Fusion H bulb. When using LED light, curing occurs in 1 to 30 minutes with a peak emission wavelength of 460±20 nm and intensity from 200 to 300 mW/cm² at a distance of 1 to 20 cm. Heat curing can be applied at temperatures between 50 to 150°C for 1 minute to 4 hours, preferably from 100 to 125°C for 2 minutes to 1 hour, or in combination with another radical cure mechanism such as UV curing. The final coatings exhibit anti-fog, wear-resistant, and water-washable properties.In a round-bottom flask, mix 19.74 g of trimethylolethane, 9.87 g of ethylene glycol, 78.97 g of POLY-G 83-34, and 276.41 g of DAA at 50°C until dissolved. Add 195.85 g of isophorone diisocyanate, 9.87 g of ETERNACOLL UH200, and 63.18 g of TEGOMER D3403 to the flask. Then, add 0.18 g of FOMREZ UL-22 and mix at 70°C for 30 minutes. Next, add 188.35 g of DAA, 15.07 g of Aerosol OT-75, 6.46 g of SCHERCOQUAT IAS-PG, 59.23 g of CIRRASOL G-265, 1.97 g of TERGITOL 15-s-7, and another 0.18 g of FOMREZ UL-22 and mix at 70°C for 1 hour. Afterward, introduce 63.18 g of 4-hydroxybutyl acrylate and 0.18 g of FOMREZ UL-22 and mix for 30 minutes at 70°C. Next, add 11.85 g of trimethylolethane and 0.18 g of UL-22, mixing for 2 hours at 70°C. Once mixing is complete, cool the flask to room temperature. After cooling, add 726 g of 1-methoxy propanol and 18.73 g of IRGACURE 1173 and mix at room temperature for 1 hour. Finally, dip-coat the sample onto a polycarbonate lens and cure using a Vela 3D (UV) cure unit at 2.0 J/cm².25.00 g of trimethylolethane, 10.00 g of ethylene glycol, 100.00 g of POLY-G 83-34, and 276.41 g of DAA were loaded into a round-bottom flask and mixed at 50°C until dissolved. 215.00 g isophorone diisocyanate, 10.00 g of ETERNACOLL UH200, and 60.00 g of TEGOMERD3403 were added to the flask. 0.18 g of FOMREZ UL-22 was then added to the flask and mixed at 70°C for 30 minutes. 125.00 g SURFCON 94 and 0.18 g FOMREZ UL-22 were added to the round-bottom flask and allowed to mix at 70°C for 1 hour. After mixing, 75.00 g 4-hydroxybutyl acrylate and 0.18 g FOMREZ UL-22 were added to the mixture and allowed to mix for 30 minutes at 70°C. 15.00 g trimethylolethane and 0.18 g UL-22 were added to the round-bottom flask and mixed for 2 hours at 70°C. After mixing, the flask was cooled to room temperature. After the mixture is cooled, 725 g 1-methoxy propanol and 20.22 g of IRGACURE 1173 were added and mixed at room temperature for 1 hour. The sample was dipcoated onto a polycarbonate lens and cured using a Vela 3D (UV) cure unit at 2.0 J/cm².7.79 g of trimethylolethane, 4.54 g of ethylene glycol, 37.63 g of POLY-G 83-34, and 181.68 g of DAA were loaded into a round-bottom flask and mixed at 50°C until dissolved. 77.86 g isophorone diisocyanate, 6.49 g of ETERNACOLL UH200, and 31.14 g of TEGOMER D3403 were added to the flask. 0.08 g of FOMREZ UL-22 was then added to the flask and mixed at 70°C for 30 minutes. 90.84 g DAA, 7.26 g Aerosol OT-75, 3.11 g SCHERCOQUAT IAS-PG, 28.55 g CIRRASOL G-265, 1.04 g TERGITOL 15-s-7, and 0.18 g FOMREZ UL-22 were added to the round-bottom flask and allowed to mix at 70°C for 1 hour. After mixing, 16.87 g 4-hydroxybutyl acrylate and 0.08 g FOMREZ UL-22 were added to the mixture and allowed to mix for 30 minutes at 70°C. 5.19 g trimethylolethane and 0.08 g UL-22 were added to the round-bottom flask and mixed for 2 hours at 70°C. After mixing, the flask was cooled to room temperature. After the mixture is cooled, 363 g 1-methoxy propanol and 9.37 g of IRGACURE 1173 were added and mixed at room temperature for 1 hour. The sample was dip-coated onto a polycarbonate lens and cured using a Vela 3D (UV) cure unit at 2.0 J/cm^2.$1.78 g of trimethylolethane, $1.75 g of ethylene glycol, $41.26 g of POLY-G 83-34, and $79.10 g of DAA were mixed together.$100\\\\mathrm{g}$ of Example 1 was mixed with $0.4\\\\ \\mathrm{g}$ of 3-EGA for 1 hour at room temperature conditions. The sample was dipcoated onto a polycarbonate lens and cured using a Vela 3D (UV) cure unit at $\\\\mathsf{2.0~J}/\\\\mathrm{cm}^{2}$.$100\\mathrm{g}$ of Example 3 was mixed with $0.4\\ \\mathrm{g}$ of 3-EGA for 1 hour at room temperature conditions. The sample was dipcoated onto a polycarbonate lens and cured using a Vela 3D (UV) cure unit at $2.0\\mathrm{J}/\\mathrm{cm}^{2}$.$100\\\\ \\mathrm{g}$ of Example 1 was mixed with $0.2\\\\ \\mathrm{g}$ of 3-EGA for 1 hour at room temperature. The sample was dip-coated onto a polycarbonate lens and cured using a Vela 3D (UV) cure unit at $2.0\\\\mathrm{J}/\\\\mathrm{cm}^{2}$.100 g of Example 3 was mixed with 0.2 g of 3-EGA for 1 hour at room temperature. The sample was dipcoated onto a polycarbonate lens and cured using a Vela 3D (UV) cure unit at 2.0 J/cm^2. Additionally, 16.50 g of IPDI, 15.20 g of 4-hydroxybutylacrylate, and 0.08 g of FOMREZ UL-22 were mixed in a round-bottom flask at 70°C for 1 hour. After cooling, 114.40 g of 1-methoxy propanol and 3.87 g of IRGACURE 1173 were added and mixed at room temperature for 1 hour. Another protocol involved loading 19.74 g of trimethylolethane, 9.87 g of ethylene glycol, 78.97 g of POLY-G 83-34, and 276.41 g of DAA into a round-bottom flask and mixed at 50°C until dissolved, followed by adding 195.85 g of isophorone diisocyanate, 9.87 g of ETERNACOLL UH200, and 63.18 g of TEGOMER D3403, then adding 0.18 g of FOMREZ UL-22 and mixing at 70°C for 30 minutes. Finally, 152.0 g of SURFCON 94 and 0.18 g of FOMREZ UL-22 were added to the round-bottom flask and mixed at 70°C for 1 hour, followed by adding 63.18 g of 4-hydroxybutyl acrylate and mixing for 30 minutes at the same temperature.To 7.00 g of the Example 9, 1.75 g of PGM-AC2140Y was added while stirring. After mixing for 15 minutes, 3.00 g of PM glycol ether was added while stirring. This was followed by the addition of 0.05 g thermal radical initiator (AIBN). Also, 0.10 g of 10% BYK 356 in PM and 0.04 g of a mixture of CAPSTONE FS35 and SCHERCOQUAT IAS-PG in the ratio 1:25 were added. The coating solution was mixed for 30 minutes. Coated parts were prepared by flow coating the liquid formulations on polycarbonate substrate. All the parts were air dried for 1 minute. Thermal curing was then initiated at 90°C for 3 minutes and completed at 90°C for 4 hours.To 7.00 g of the Example 9, 1.75 g of PGM-AC2140Y was added while stirring. After mixing for 15 minutes, 3.00 g of PM glycol ether was added while stirring. This was followed by addition of 0.05 g thermal radical initiator (VAM-110). 0.10 g of 10% BYK 356 in PM, and 0.04 g of mixture of CAPSTONE FS35 and SCHERCOQUAT IAS-PG in the ratio 1:25, were added. The coating solution was mixed for 30 min. Coated parts were prepared by flow coating the liquid formulations on polycarbonate substrate. All the parts were air dried for 1 min. Thermal curing was then initiated at 90°C for 3 min and completed at 115°C for 2h.Another set of coated parts using the same liquid formulation of Example 11 were prepared by flow coating on polycarbonate substrates. Parts were air dried for 1 min. Thermal curing was then initiated at 90°C for 3 min and completed at 110°C for 45 min.To 7.00 g of the Example 9, 1.75 g of PGM-AC2140Y was added while stirring. After mixing for 15 minutes, 3.00 g of PM glycol ether was added while stirring. This was followed by addition of 0.05 g thermal radical initiator (VA-086). 0.10 g of 10% BYK 356 in PM, and 0.04 g of mixture of CAPSTONE FS35 and SCHERCOQUAT IAS-PG in the ratio 1:25, were added. The coating solution was mixed for 30 minutes. Coated parts were prepared by flow coating the liquid formulations on polycarbonate substrate. All the parts were air dried for 1 minute. Thermal curing was then initiated at 90°C for 3 minutes and completed at 100°C for 4 hours.To 50.00 g of Example 9, 0.74 g of IRGACURE 184 and 30.00 g of a 10% mix of SOKALAN K17 in PM were added. The mixture was agitated for at least 20 minutes prior to coating. Coated parts were prepared by flow coating the liquid formulations on polycarbonate substrate. All the parts were air dried for 1 min and initially thermally cured at 90°C for 3 min. The cure was completed using a Vela 3D (UV) Cure Unit at 2.0 J/cm².To 50.00 g of Example 9, 0.74 g of IRGACURE 184 and 10.00 g of a 30% K60 in water were added. After mixing for 2 minutes, 20.00 g of PM was added to the beaker. The mixture was agitated for at least 20 minutes prior to coating. Coated parts were prepared by flow coating the liquid formulations on polycarbonate substrate. All the parts were air dried for 1 minute, and initially thermally cured at 90°C for 3 minutes. The cure was completed using a Vela 3D (UV) cure unit at 2.0 J/cm².1. Mix anhydrous citric acid (34.6 g), polyethylene glycol diglycidyl ether (200) (207.6 g) at 90°C. 2. Add dimethylamine hydrochloride (3 g) and stir for 3 hours. 3. Incorporate acrylic acid (57.9 g). 4. Add hydroquinone (0.3 g). 5. Prepare formulations using Synthesis II products as specified in Table 10. 6. Apply to polycarbonate substrate. 7. Cure with Fusion Conveyor (UV) cure unit.100 g of Example 2 was mixed with 0.25 g of azobisisobutyronitrile (AIBN) overnight at room temperature. The sample was dipcoated onto a polycarbonate lens. Samples were initially cured at 90°C for at least 5 minutes and cure was completed using a Vela 3D (UV) cure unit at 2.0 J/cm².100 g of Example 2 was mixed with 0.38 g of AIBN overnight at room temperature. The sample was dipcoated onto a polycarbonate lens. Samples were initially cured at 90°C for at least 5 minutes and cure was completed using a Vela 3D (UV) cure unit at 2.0 J/cm²."
}