# US 2024/0201420 A1 · Method of producing an optical material and optical material > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2024/0201420 A1 - Document ID: US20240201420A1 - Status: Published application - Kind: A1 - Application number: 18/288,298 - Filed: 2022-04-29 - Published: 2024-06-20 - Earliest claimed: 2021-04-29 - Assignees: Essilor International - Applicants: Essilor International - Inventors: Jianwei ZHANG; Laurent CHIPPAUX - Web page: https://patentgrep.com/patent/US20240201420A1 ## CPC - G02B 1/041: {Lenses} - B29D 11/00442: {Curing the lens material} - C08F 20/00: Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride, ester, amide, imide or nitrile thereof - G02C 7/02: Lenses; Lens systems {; Methods of designing lenses} - G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - C08F: MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS - G02C: SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES (trial frames for testing the eyes A61B3/04; goggles or eyeshields not having the same features as spectacles A61F9/00) ## Abstract A method of producing an optical material, wherein a polymerizable composition intended to polymerize to form the optical material comprises: a) monomeric compounds adapted to polymerize, b) at least one catalyst for initiating the polymerization of said monomeric compounds, and c) from more than 1,500 ppm to 3,000 ppm of a release agent, as compared to the total weight of the polymerizable composition, and wherein said polymerizable composition is polymerized under a polymerization cycle including a plurality of steps, the global duration of the polymerization cycle being of less than 19 hours. ## Claims ### Claim 1 A method of producing an optical material, wherein a polymerizable composition intended to polymerize to form the optical material comprises: a) monomeric compounds adapted to polymerize; b) at least one catalyst for initiating the polymerization of said monomeric compounds; and c) from more than 1,500 ppm to 3,000 ppm of a release agent, as compared to the total weight of the polymerizable composition; wherein said polymerizable composition is polymerized under a polymerization cycle including a plurality of steps, the global duration of the polymerization cycle being of less than 17 hours. ### Claim 2 (depends on 1) The method of claim 1, wherein the global duration of the polymerization cycle is of at least 15 hours. ### Claim 3 (depends on 1) The method of claim 1, wherein the polymerizable composition comprises from 1,900 ppm to 2,100 ppm of release agent as compared to the total weight of the polymerizable composition. ### Claim 4 (depends on 1) The method of claim 1, wherein the polymerizable composition comprises from 20,000 ppm to 35,000 ppm of the at least one catalyst as compared to the total weight of the polymerizable composition. ### Claim 5 (depends on 1) The method of claim 1, wherein the polymerization cycle includes the following steps: heating for a duration of 5.25 hours from about 25° C. to about 40° C.; increasing the temperature from 40° C. to about 85° C. during 7 to 10 hours at a speed ranging from about 5° C./hour to 9° C./hour; and cooling for 3 hours from 85° C. to about 75° C. ### Claim 6 (depends on 5) The method of claim 5, wherein the step of heating from about 25° C. to 40° ° C. includes at least: a first sub-step of heating at a speed faster than 50° C./hour for a duration shorter than an hour; a second sub-step of maintaining a constant temperature at which is initiated the polymerization, for a duration longer than the duration of the first sub-step, said constant temperature being higher than or equal to 35° C. and strictly lower than 40° C.; and a third sub-step of heating at a speed slower than 1° C./hour for a duration longer than the duration of the second sub-step. ### Claim 7 (depends on 5) The method of claim 5, wherein the step of increasing of the temperature from 40° C. to 85° C. comprises at least a first sub-step of heating at a speed of at least 5° C./hour followed by a second sub-step of heating at a speed faster than the speed of the first sub-step, for a duration shorter than the duration of the first sub-step. ### Claim 8 (depends on 1) The method of claim 1, wherein the monomeric compounds include acrylic monomeric compounds adapted to polymerize to form an acrylic substrate or allylic monomeric compounds adapted to polymerize to form an allylic substrate. ### Claim 9 (depends on 1) The method of claim 1, wherein said polymerizable composition comprises from 30,000 ppm to 32,000 ppm of said at least one catalyst for initiating the polymerization, as compared to the total weight of the polymerizable composition. ### Claim 10 (depends on 1) The method of claim 1, wherein said at least one catalyst for initiating the polymerization is a peroxicarbonate, a peroxodicarbonate, a peroxyester or a perketal. ### Claim 11 (depends on 1) The method of claim 1, wherein said release agent is a polyoxyethylene alkyl ether phosphate. ### Claim 12 (depends on 1) The method of claim 1, wherein the optical material is obtained by demolding the polymerized composition with a mean force lower than or equal to 1,400 Newton. ### Claim 13 (depends on 1) An optical material obtained by the method of claim 1, wherein the optical material exhibits a refraction index of 1.56. ### Claim 14 (depends on 13) The optical material of claim 13, wherein said optical material is an ophthalmic lens. ### Claim 15 (depends on 10) The method claim 10, wherein said at least one catalyst for initiating the polymerization is a diisopropyl peroxydicarbonate.