Photochromic polyurethane laminate
Photochromic polyurethane laminates and methods for the formation of same wherein a photochromic polyurethane layer of the laminate is interposed between two primer coated transparent resin sheets.
1. A photochromic polyurethane laminate for use in an optical article comprising:
a first resin sheet;
a first primer layer coated on the first resin sheet;
a second resin sheet;
a second primer layer coated on the second resin sheet; and
a photochromic polyurethane film having a first side attached to the first primer layer and a second side attached to the second primer layer, said photochromic polyurethane formed of a composition comprising:
a hydroxyl-terminated polyurethane;
an isocyanate-terminated polyurethane prepolymer; and
at least one photochromic compound;
the first and the second primer layers formed from a composition comprising an isocyanate-terminated polyurethane prepolymer that is the same as the isocyanate-terminated polyurethane prepolymer employed to form the photochromic polyurethane film.
2. The photochromic polyurethane laminate of claim 1 wherein said hydroxyl-terminated polyurethane is formed from a composition comprising:
(a) at least one diisocyanate selected from a group consisting of aliphatic diisocyanate and cycloaliphatic diisocyanate; and
(b) at least one polyol selected from a group consisting of:
(i) a polycarbonate polyol having a Formula I:
where n is equal to an integer from 3 to 6 or a combination thereof, and x is an integer that makes the molecular weight of the at least one polyol approximately equal to 500-2500 Daltons;
(ii) a polyether polyol having a molecular weight approximately equal to 500-2500 Daltons; and
(iii) a polyester polyol having a Formula III:
wherein x is an integer that makes the molecular weight of the at least one polyol approximately equal to 500-2500 Daltons.
3. The photochromic polyurethane laminate of claim 1 wherein said isocyanate-terminated polyurethane prepolymer is formed from a composition comprising:
(a) at least one diisocyanate selected from a group consisting of aliphatic diisocyanate and cycloaliphatic diisocyanate; and
(b) at least one polyol selected from a group consisting of:
(i) a polycarbonate polyol having a Formula I:
where n is equal to an integer from 3 to 6 or a combination thereof, and x is an integer that makes the molecular weight of the at least one polyol approximately equal to 500-2500 Daltons;
(ii) a polyether polyol having a molecular weight approximately equal to 500-2500 Daltons; and
(iii) a polyester polyol having a Formula III:
wherein x is an integer that makes the molecular weight of the at least one polyol approximately equal to 500-2500 Daltons.
4. The photochromic polyurethane laminate of claim 1 wherein the first and second primer layers are formed of a composition comprising an isocyanate-terminated polyurethane prepolymer having a molecular weight of about 59,995 Daltons.
5. The photochromic polyurethane laminate of claim 1 wherein said isocyanate-terminated polyurethane prepolymer employed in the first and second primer layers is formed of a composition comprising:
at least one diisocyanate selected from a group consisting of aliphatic diisocyanate and cycloaliphatic diisocyanate; and
a polyol comprising;
where n is equal to an integer from 3 to 6 or a combination thereof, and x is an integer that makes the molecular weight of the polyol approximately equal to 500-2500 Daltons.
6. The photochromic polyurethane laminate of claim 1 wherein the first and second primer layers have a thickness in a range of 0.3 to 8 micrometers.
7. The photochromic polyurethane laminate of claim 1 wherein the hydroxyl-terminated polyurethane has a molecular weight of about 66,210 Daltons.
8. The photochromic polyurethane laminate of claim 1 wherein said photochromic polyurethane laminate is cured within a temperature range from about 50 degrees Celsius to about 130 degrees Celsius.
9. A photochromic polyurethane laminate for use in an optical article comprising:
a photochromic polyurethane film interposed between two primer coated transparent resin sheets;
the photochromic polyurethane film formed of a composition comprising:
a hydroxyl-terminated polyurethane formed by reacting a first polyol with an aliphatic diisocyanate or a cycloaliphatic diisocyanate and a chain extender;
an isocyanate-terminated polyurethane prepolymer formed by reacting a second polyol with an aliphatic diisocyanate or a cycloaliphatic diisocyanate; and
at least one photochromic compound;
the primer of the two primer coated transparent resin sheets formed from a composition comprising an aliphatic diisocyanate or a cycloaliphatic diisocyanate and the same polyol employed for forming the isocyanate-terminated polyurethane prepolymer.
10. The photochromic polyurethane laminate of claim 9 wherein
the first polyol is selected from a group consisting of:
(i) a polycarbonate polyol having a Formula I:
where n is equal to an integer from 3 to 6 or a combination thereof, and x is an integer that makes the molecular weight of the at least one polyol approximately equal to 500-2500 Daltons;
(ii) a polyether polyol having a molecular weight approximately equal to 500-2500 Daltons; and
(iii) a polyester polyol having a Formula III:
wherein x is an integer that makes the molecular weight of the at least one polyol approximately equal to 500-2500 Daltons.
11. The photochromic polyurethane laminate of claim 9 wherein
the second polyol is selected from a group consisting of:
(i) a polycarbonate polyol having a Formula I:
where n is equal to an integer from 3 to 6 or a combination thereof, and x is an integer that makes the molecular weight of at least one polyol approximately equal to 500-2500 Daltons;
(ii) a polyether polyol having a molecular weight approximately equal to 500-2500 Daltons; and
(iii) a polyester polyol having a Formula III:
wherein x is an integer that makes the molecular weight of the at least one polyol approximately equal to 500-2500 Daltons.
12. The photochromic polyurethane laminate of claim 9 wherein the primer is formed of a polyol comprising;
where n is equal to an integer from 3 to 6 or a combination thereof, and x is an integer that makes the molecular weight of the polyol approximately equal to 500-2500 Daltons.
13. The photochromic polyurethane laminate of claim 9 wherein said photochromic polyurethane laminate further comprises a molecular structure resulting from curing said laminate within a temperature range from about 50 degrees Celsius to about 130 degrees Celsius.
14. The photochromic polyurethane laminate of claim 9 wherein the hydroxyl-terminated polyurethane has a molecular weight of about 66,210 Daltons.
15. The photochromic polyurethane laminate of claim 9 wherein the primer of the two primer coated transparent resin sheets has a thickness in a range of 0.3 to 8 micrometers.
16. The photochromic polyurethane laminate of claim 9 wherein the isocyanate-terminated polyurethane prepolymer has a molecular weight of about 59,995 Daltons.
17. The photochromic polyurethane laminate of claim 1 wherein the first and the second primer layers are formed from a composition further comprising at least one component selected from a group consisting of a hydroxyl-terminated chain extender and a hydroxyl-terminated crosslinking agent.