Abstract: This invention is directed to a processing approach for the rapid and efficient in-situ polymerization of specially prepared precursor mixtures to achieve near-net-shape production of objects/articles with exact dimensions. The process relies on the use of polymerizable compositions comprised of a mixture of a dead polymer, a reactive plasticizer and, optionally, an initiator, which compositions are semi-solid-like prior to curing and induce low shrinkage upon curing as a result of their partially polymerized nature prior to processing. The partially polymerized nature of the precursor mixtures also allows extremely impact-resistant objects/articles to be fabricated. Other desirable engineering property attributes can similarly be achieved via the judicious blending of starting ingredients in formulating the polymerizable (curable) mixtures.

Abstract: This disclosure describes a processing approach for the rapid and efficient in-situ polymerization of specially prepared precursor mixtures to achieve near-net-shape production of objects/articles with exact dimensions. The process relies on the use of polymerizable compositions comprised of a mixture of a reactive plasticizer and an initiator, optionally also including a dead polymer, which compositions are semi-solid-like and induce little shrinkage upon curing as a result of their partially polymerized nature prior to processing. The articles of the invention have a surface and an interior core, the composition of the surface material being distinct from the composition of the core material while at the same time the surface and the core are an integral, monolithic entity. In addition, the articles are dimensionally stable and exhibit high fidelity replication.

Abstract: This invention is directed to a processing approach for the rapid and efficient in-situ polymerization of specially prepared precursor mixtures to achieve near-net-shape production of objects/articles with exact dimensions. The process relies on the use of polymerizable compositions comprised of a mixture of a dead polymer, a reactive plasticizer and, optionally, an initiator, which compositions are semi-solid-like prior to curing and induce low shrinkage upon curing as a result of their partially polymerized nature prior to processing. The partially polymerized nature of the precursor mixtures also allows extremely impact-resistant objects/articles to be fabricated. Other desirable engineering property attributes can similarly be achieved via the judicious blending of starting ingredients in formulating the polymerizable (curable) mixtures.

Abstract: This disclosure describes a processing approach for the rapid and efficient in-situ polymerization of specially prepared precursor mixtures to achieve near-net-shape production of objects/articles with exact dimensions. The process relies on the use of polymerizable compositions comprised of a mixture of a dead polymer, a reactive plasticizer and an initiator, which compositions are semi-solid-like prior to curing and induce low shrinkage upon curing as a result of their partially polymerized nature prior to processing. The partially polymerized nature of the precursor mixtures also allows extremely impact-resistant objects/articles to be fabricated. Other desirable engineering property attributes can similarly be achieved via the judicious blending of starting ingredients in formulating the polymerizable (curable) mixtures.

Abstract: This disclosure describes a processing approach for the rapid and efficient in-situ polymerization of specially prepared precursor mixtures to achieve near-net-shape production of objects/articles with exact dimensions. The process relies on the use of polymerizable compositions comprised of a mixture of a reactive plasticizer and an initiator, optionally also including a dead polymer, which compositions are semi-solid-like and induce little shrinkage upon curing as a result of their partially polymerized nature prior to processing. The articles of the invention have a surface and an interior core, the composition of the surface material being distinct from the composition of the core material while at the same time the surface and the core are an integral, monolithic entity. In addition, the articles are dimensionally stable and exhibit high fidelity replication.

Abstract: This disclosure describes a processing approach for the rapid and efficient in-situ polymerization of specially prepared precursor mixtures to achieve near-net-shape production of objects/articles with exact dimensions. The process relies on the use of polymerizable compositions comprised of a mixture of a reactive plasticizer and an initiator, optionally also including a dead polymer, which compositions are semi-solid-like and induce little shrinkage upon curing as a result of their partially polymerized nature prior to processing. The articles of the invention have a surface and an interior core, the composition of the surface material being distinct from the composition of the core material while at the same time the surface and the core are an integral, monolithic entity. In addition, the articles are dimensionally stable and exhibit high fidelity replication.

Abstract: This invention is directed to a process for the rapid in-situ curing of polymerizable materials to provide macromolecular networks and articles of manufacture that are “morphology-trapped”; that is, they exhibit a fixed phase morphology and/or molecular orientation that is locked in by the curing step. The process includes the steps of mixing together a dead polymer, a reactive plasticizer and an initiator to give a polymerizable composition; further processing the mixture in order to achieve a desired phase morphology and/or molecular orientation of the polymeric constituents; shaping the polymerizable composition into a desired geometry; and exposing the polymerizable composition to a source of polymerizing energy, without mixing, to give a final product with the desired phase morphology and/or molecular orientation locked in place.

Abstract: This invention is directed to a process for the rapid in-situ curing of polymerizable materials to provide macro-molecular networks and articles of manufacture that are “morphology-trapped”; that is, they exhibit a fixed phase morphology and/or molecular orientation that is locked in by the curing step. The process includes the steps of mixing together a dead polymer or a prepolymer, a reactive plasticizer or a diulent, and an initiator to give a polymerizable composition; further processing the mixture in order to achieve a desired phase morphology and/or moelcular orientation of the polymeric constitutents; shaping the polymerizable composition into a desired geometry; and exposing the polymerizable composition to a source of polymerizing energy, without mixing to give a final product with the desired phase morphology and/or moelcular orientation locked in place.

Abstract: The invention is directed to a method for making composite articles, including optical lenses, which includes the steps of obtaining a substrate; placing a semi-solid-like polymerizable composition in contact with at least one of the front or back surface of the substrate; compressing or heating the resulting semi-solid/substrate sandwich between two mold halves, where the mold contacting the semi-solid polymerizable material has a desired surface geometry; and exposing the semi-solid/substrate sandwich to a source of polymerizing energy. The resulting composite article has the desirable characteristics of the substrate but is also easily fabricated as a result of the semi-solid molding process. Also included within the present invention is a composite article comprising a substrate portion and at least one layer of a cured resin bonded to the substrate portion, the cured resin comprising an interpenetrating crosslinked polymer network of reactive plasticizer within a dead polymer.

Abstract: The present invention relates to a process for the production of polymeric moldings, such as medical device moldings and optical and ophthalmic lenses, preferably contact lenses and intraocular lenses. The invention also relates to a polymeric precursor mixture useful in polymeric moldings and to methods of making and using the polymeric precursor mixture.

Abstract: This invention is directed to a process for the rapid in-situ curing of polymerizable materials to provide macromolecular networks and articles of manufacture that are “morphology-trapped”; that is, they exhibit a fixed phase morphology and/or molecular orientation that is locked in by the curing step. The process includes the steps of mixing together a dead polymer, a reactive plasticizer and an initiator to give a polymerizable composition; further processing the mixture in order to achieve a desired phase morphology and/or molecular orientation of the polymeric constituents; shaping the polymerizable composition into a desired geometry; and exposing the polymerizable composition to a source of polymerizing energy, without mixing, to give a final product with the desired phase morphology and/or molecular orientation locked in place.

Abstract: This invention is directed to a processing approach for the rapid and efficient in-situ polymerization of specially prepared precursor mixtures to achieve near-net-shape production of objects/articles with exact dimensions. The process relies on the use of polymerizable compositions comprised of a mixture of a dead polymer, a reactive plasticizer and, optionally, an initiator, which compositions are semi-solid-like prior to curing and induce low shrinkage upon curing as a result of their partially polymerized nature prior to processing. The partially polymerized nature of the precursor mixtures also allows extremely impact-resistant objects/articles to be fabricated. Other desirable engineering property attributes can similarly be achieved via the judicious blending of starting ingredients in formulating the polymerizable (curable) mixtures.

Abstract: This invention is directed to a processing approach for the rapid and efficient in-situ polymerization of specially prepared precursor mixtures to achieve near-net-shape production of objects/articles with exact dimensions. The process relies on the use of polymerizable compositions comprised of a mixture of a dead polymer, a reactive plasticizer and, optionally, an initiator, which compositions are semi-solid-like prior to curing and induce low shrinkage upon curing as a result of their partially polymerized nature prior to processing. The partially polymerized nature of the precursor mixtures also allows extremely impact-resistant objects/articles to be fabricated. Other desirable engineering property attributes can similarly be achieved via the judicious blending of starting ingredients in formulating the polymerizable (curable) mixtures.

Abstract: This disclosure describes a processing approach for the rapid and efficient in-situ polymerization of specially prepared precursor mixtures to achieve near-net-shape production of objects/articles with exact dimensions. The process relies on the use of polymerizable compositions comprised of a mixture of a dead polymer, a reactive plasticizer and an initiator, which compositions are semi-solid-like prior to curing and induce low shrinkage upon curing as a result of their partially polymerized nature prior to processing. The partially polymerized nature of the precursor mixtures also allows extremely impact-resistant objects/articles to be fabricated. Other desirable engineering property attributes can similarly be achieved via the judicious blending of starting ingredients in formulating the polymerizable (curable) mixtures.

Abstract: This disclosure describes a processing approach for the rapid and efficient in-situ polymerization of specially prepared precursor mixtures to achieve near-net-shape production of objects/articles with exact dimensions. The process relies on the use of polymerizable compositions comprised of a mixture of a dead polymer, a reactive plasticizer and an initiator, which compositions are semi-solid-like prior to curing and induce low shrinkage upon curing as a result of their partially polymerized nature prior to processing. The partially polymerized nature of the precursor mixtures also allows extremely impact-resistant objects/articles to be fabricated. Other desirable engineering property attributes can similarly be achieved via the judicious blending of starting ingredients in formulating the polymerizable (curable) mixtures.

Abstract: This disclosure describes a processing approach for the rapid and efficient in-situ polymerization of specially prepared precursor mixtures to achieve near-net-shape production of objects/articles with exact dimensions. The process relies on the use of polymerizable compositions comprised of a mixture of a dead polymer, a reactive plasticizer and an initiator, which compositions are semi-solid-like prior to curing and induce low shrinkage upon curing as a result of their partially polymerized nature prior to processing. The partially polymerized nature of the precursor mixtures also allows extremely impact-resistant objects/articles to be fabricated. Other desirable engineering property attributes can similarly be achieved via the judicious blending of starting ingredients in formulating the polymerizable (curable) mixtures.

Abstract: This invention is directed to a process for the rapid in-situ curing of polymerizable materials to provide macromolecular networks and articles of manufacture that are “morphology-trapped”; that is, they exhibit a fixed phase morphology and/or molecular orientation that is locked in by the curing step. The process includes the steps of mixing together a dead polymer, a reactive plasticizer and an initiator to give a polymerizable composition; further processing the mixture in order to achieve a desired phase morphology and/or molecular orientation of the polymeric constituents; shaping the polymerizable composition into a desired geometry; and exposing the polymerizable composition to a source of polymerizing energy, without mixing, to give a final product with the desired phase morphology and/or molecular orientation locked in place.

Abstract: The invention is directed to a method for making composite articles, including optical lenses, which includes the steps of obtaining a substrate; placing a semi-solid-like polymerizable composition in contact with at least one of the front or back surface of the substrate; compressing or heating the resulting semi-solid/substrate sandwich between two mold halves, where the mold contacting the semi-solid polymerizable material has a desired surface geometry; and exposing the semi-solid/substrate sandwich to a source of polymerizing energy. The resulting composite article has the desirable characteristics of the substrate but is also easily fabricated as a result of the semi-solid molding process. Also included within the present invention is a composite article comprising a substrate portion and at least one layer of a cured resin bonded to the substrate portion, the cured resin comprising an interpenetrating crosslinked polymer network of reactive plasticizer within a dead polymer.

Abstract: The invention is directed to a method for making composite optical lenses, which includes the steps of obtaining an optical lens “core”; placing a semi-solid-like polymerizable composition in contact with at least one of the front or back surface of the core; compressing or heating the resulting semi-solid/core sandwich between two mold halves, where the mold contacting the semi-solid polymerizable material has a desired surface geometry; and exposing the semi-solid/core sandwich to a source of polymerizing energy. The resulting composite lens has the desirable characteristics of the core but is also easily fabricated with both toroidal curves and multi-focal pockets as a result of the semi-solid molding process.

Abstract: This disclosure describes a processing approach for the rapid and efficient in-situ polymerization of specially prepared precursor mixtures to achieve near-net-shape production of objects/articles with exact dimensions. The process relies on the use of polymerizable compositions comprised of a mixture of a reactive plasticizer and an initiator, optionally also including a dead polymer, which compositions are semi-solid-like and induce little shrinkage upon curing as a result of their partially polymerized nature prior to processing. The articles of the invention have a surface and an interior core, the composition of the surface material being distinct from the composition of the core material while at the same time the surface and the core are an integral, monolithic entity. In addition, the articles are dimensionally stable and exhibit high fidelity replication.