Method of manufacturing a replica as well as a replica obtained by carrying out an uv light-initiated cationic polymerization

Abstract

The invention relates to a method of manufacturing a replica, which method comprises the provision of a polymerizable resin composition between a front mold having a pre-shaped surface and a back mold having a pre-shaped surface, carrying out a curing treatment and removing the replica thus manufactured from the molds. The invention further relates to a replica obtained by carrying out a UV light-initiated cationic polymerization.

1 . A method of manufacturing a replica, which method comprises the provision of a reactive mixture which comprises a polymerizable resin composition between a front mold having a pre-shaped surface, and a back mold having a pre-shaped surface, carrying out a curing treatment and removing the replica thus manufactured from the molds, which replica comprises a solid body onto which the shape of the surface of the front mold and the shape of the surface of the back mold have been reproduced, wherein the curing treatment is a UV-light initiated cationic polymerization, the resin composition used is a compound comprising at least two cationically polymerizable cyclic ether groups, which only shows signs of gelation when at least 30% of the conversion that can be achieved in the mold under the relevant curing conditions has taken place.  
   
   
       2 . A method as claimed in  claim 1 , characterized in that the resin composition further comprises a reactive diluent.  
   
   
       3 . (canceled)  
   
   
       4 . A method as claimed in  claim 1 , characterized in that the compound is selected from the group consisting of 1,2,7,8-diepoxyoctane, 3,4-epoxycyclohexylmethyl-3′,4′-epoxycyclohexanecarboxylate, bis(3,4-epoxycyclohexylmethyl)adipate, bis(3,4-epoxy-6-methylcyclohexylmethyl)adipate and C 12 -C 14 -alkylglycidylether and the corresponding oxetane compounds thereof, in particular 1,4-bis[(3-ethyl-3-oxetanylmethoxy)methyl]benzene.  
   
   
       5 . (canceled)  
   
   
       6 . A replica obtained by carrying out a UV light-initiated cationic polymerization of a compound comprising at least two cationically polymerizable cyclic ether groups, which compound only exhibits gelation when at least 30% of the conversion that can be achieved in the mold under the relevant curing conditions has taken place, optionally in the presence of a reactive diluent.  
   
   
       7 . A replica as claimed in  claim 6 , characterized in that this replica comprises a solid body having a relief structure on a at least one side, which relief structure must meet high (sub-micron) requirements with a view to the necessary accuracy of form.  
   
   
       8 . A replica as claimed in claims  claim 6 , characterized in that the replica obtained is an optical component.  
   
   
       9 . A replica as claimed in  claim 8 , characterized in that the optical component obtained is an (a) spherical lens, a lens array, a prism, a grating or another relief structure for optical applications, or a combination thereof.  
   
   
       10 . (canceled)  
   
   
       11 . A replica as claimed in  claim 6 , characterized in that the compound is selected from the group consisting of 1,2,7,8-diepoxyoctane, 3,4-epoxycyclohexylmethyl-3′,4′-epoxycyclohexanecarboxylate, bis(3,4-epoxycyclohexylmethyl)adipate, bis(3,4-epoxy-6-methylcyclohexylmethyl)adipate and C 12 -C 14 -alkylglycidylether and the corresponding oxetane compounds thereof, in particular 1,4-bis[(3-ethyl-3-oxetanylmethoxy)methyl]benzene.  
   
   
       12 . (canceled)  
   
   
       13 . A replica as claimed in  claim 7 , characterized in that the replica obtained is an optical component.  
   
   
       14 . A replica as claimed in  claim 13 , characterized in that the optical component obtained is an (a) spherical lens, a lens array, a prism, a grating or another relief structure for optical applications, or a combination thereof.  
   
   
       15 . A method of manufacturing a replica, which method comprises the provision of a reactive mixture which comprises a polymerizable resin composition between a front mold having a pre-shaped surface, and a back mold having a pre-shaped surface, carrying out a curing treatment and removing the replica thus manufactured from the molds, which replica comprises a solid body onto which the shape of the surface of the front mold and the shape of the surface of the back mold have been reproduced, wherein the curing treatment is a UV-light initiated cationic polymerization, the resin composition used is a compound comprising at least two cationically polymerizable cyclic ether groups, which only shows signs of gelation when at least 30% of the conversion that can be achieved in the mold under the relevant curing conditions has taken place, and wherein during the polymerization process the reactive mixture exhibits comparatively less shrinkage than that exhibited by reactive mixtures that do not comprise said compound under said relevant curing conditions.  
   
   
       16 . A method as claimed in  claim 15 , characterized in that the resin composition further comprises a reactive diluent.  
   
   
       17 . A method as claimed in  claim 15 , characterized in that the compound is selected from the group consisting of 1,2,7,8-diepoxyoctane, 3,4-epoxycyclohexylmethyl-3′,4′-epoxycyclohexanecarboxylate, bis(3,4-epoxycyclohexylmethyl)adipate, bis(3,4-epoxy-6-methylcyclohexylmethyl)adipate and C 12 -C 14 -alkylglycidylether and the corresponding oxetane compounds thereof, in particular 1,4-bis[(3-ethyl-3-oxetanylmethoxy)methyl]benzene.  
   
   
       18 . A replica obtained by carrying out a UV light-initiated cationic polymerization of a reactive mixture which comprises a compound comprising at least two cationically polymerizable cyclic ether groups, which compound only exhibits gelation when at least 30% of the conversion that can be achieved in the mold under the relevant curing conditions has taken place, optionally in the presence of a reactive diluent, and wherein during the polymerization process the reactive mixture exhibits comparatively less shrinkage than that exhibited by reactive mixtures that do not comprise said compound under said relevant curing conditions.  
   
   
       19 . A replica as claimed in  claim 18 , characterized in that the replica comprises a solid body having a relief structure on at least one side, which relief structure must meet high (sub-micron) requirements with a view to the necessary accuracy of form.  
   
   
       20 . A replica as claimed in  claim 19 , characterized in that the optical component obtained is an (a) spherical lens, a lens array, a prism, a grating or another relief structure for optical applications, or a combinations thereof.  
   
   
       21 . A replica as claimed in  claim 20 , characterized in that the compound is selected from the group consisting of 1,2,7,8-diepoxyoctane, 3,4-epoxycyclohexylmethyl-3′,4′-epoxycyclohexanecarboxylate, bis(3,4-epoxycyclohexylmethyl)adipate, bis(3,4-epoxy-6-methylcyclohexyl-methyl)adipate and C 12 -C 14 -alkylglycidylether and the corresponding oxetane compounds thereof, in particular 1,4-bis[(3-ethyl-3-oxetanylmethoxy)methyl]benzenes.