Plastic lenses having a high-refractive index, process for the preparation thereof and casting polymerization process for preparing sulfur containing urethane resin lens and lens prepared thereby

Abstract

One aspect of the present invention relates to a process for preparing plastic lenses having a high-refractive index comprising forming a mixture containing one or more polyisocyanate compounds; one or more active hydrogen compounds selected from the group consisting of a polyol compound having no sulfur atom, a polyol compound having at least one sulfur atom, and a polythiol compound having at least one sulfur atom in addition to the sulfur atom contained in mercapto group and at least one internal releasing agent and then casting and polymerizing the mixture.A second aspect of the present invention relates to a process for preparing a sulfur-containing urethane resin lens is here disclosed which comprises mixing polyisocyanate having two or more isocyanato groups, polythiol having two or more thiol groups and one or more surface active agent selected from the group consisting of fluorine-containing nonionic surface active agents, silicone-containing nonionic surface active agents, alkyl quaternary ammonium salts and acid phosphoric esters and then cast polymerizing the mixture in a mold made of a glass or a metal. Lenses prepared by the processes are also disclosed.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to plastic lenses and processes for preparing the same. More specifically, one aspect of the present invention relates to a method for preparing plastic lenses having a high-refractive index, high surface accuracy and excellent optical properties. Another aspect of the present invention relates to a process for preparing a sulfur-containing urethane resin lens which comprises cast polymerizing a mixture of a polyisocyanate having two or more isocyanato groups, a polythiol having two or more thiol groups and a specific surface active agent, and to a lens prepared by the process.

2. Description of the Related Art

Plastic lenses that are used in optical applications must be completely free from bubbles and must have high surface accuracy and optical homogeneity such that no strain can be found by an optical strain meter, and must also have high transparency. Conventionally, diethylene glycol bis(allylcarbonate) (hereinafter abbreviated as DAC), PMMA, and polycarbonates have been used as materials for lenses. Generally, in the process for preparing plastic lenses, cutting and abrading, hot press molding, cast molding, injection molding or the like have been employed. When a thermosetting resin such as DAC is used, cast molding is employed.

In this case, the releasability between the lens and the mold is important. If the release is premature, the lens surface is disordered and the lens tends to exhibit strain. Conversely if the release is difficult, exfoliation of the mold takes place, and exfoliated pieces of the mold stick to the surface of the lens. Although it is known that butyl phosphate is used as an internal release agent for DAC, generally it is not preferable to use an internal release agent in view of the physical properties of the lens (see "Polymer Digest" by Seiichi Mima, 3, 39 (1984).

On the other hand, as a sulfur-containing urethane resin for a lens and a lens prepared therefrom, U.S. Pat. No. 4,689,387 has suggested a thiocarbamic acid S-alkyl ester resin and a lens which can be obtained from a polyisocyanate and a polythiol.

When the thiocarbamic acid S-alkyl ester lens is molded, it is usually impossible to release the polymerized lens from the mold due to excessive adhesion between the lens and the mold.

Therefore, as a method of improving the releasability thereof, a process in which an external release agent is used was proposed by U.S. Pat. No. 4,689,387, and a process in which a polyolefin resin mold is used was proposed by Japanese Patent Laid-Open Publication No. 236818/1987.

However, a process wherein a fluorine type external release agent or a silicone type external release agent is used to form a release film on the mold is accompanied by such problems that it is difficult for the thickness of the release film to be uniform, which makes it difficult to maintain the surface accuracy of the lens. Further, in such a process, a part or all of the release film migrates to the surface of the polymerized lens or into the inside of the polymerized lens and deteriorates the surface state of the lens. In particular, the surface becomes nonuniform and the lens becomes turbid.

In addition, the adhered release agent on the surface of the lens must be removed therefrom, and it is necessary to treat the mold with the release agent every time the mold is used. Thus, the process is intricate and cannot provide high productivity, which means that it is very uneconomical.

As a consequence, a process using an external release agent which involves high cost cannot be employed as an industrial production process.

On the other hand, in a process wherein a mold of a polyolefin resin is employed, the resin mold deforms at elevated temperatures which causes large profile irregularities on the molded lens and thus is impractical for use in the field of optical lenses wherein high surface accuracy is required.

SUMMARY OF THE INVENTION

The present invention overcomes the problems and disadvantages of the prior art by providing, in one aspect, a process for preparing plastic lenses having a high refractive index, superior surface accuracy and superior optical properties than prior art plastic lenses.

One object of the first aspect of the present invention is to provide colorless and transparent plastic lenses suitable for use in eyeglasses and cameras and processes for producing the same.

Another object is to provide plastic lenses having high surface accuracy and excellent optical properties and processes for producing the same.

It is a further object to provide plastic lenses that are lightweight and have a high refractive index and processes for producing the same.

It is an additional object to provide plastic lenses that are excellent in impact resistance and processes for producing the same.

In a second aspect of the present invention, it is an object to provide a process for preparing a sulfur-containing urethane resin lens having high surface accuracy by using a specific surface active agent as an internal release agent.

It is another object to provide a process for preparing a sulfur-containing urethane resin lens having high transparency by using a specific surface active agent as an internal release agent.

It is a further object to provide a process for preparing a sulfur-containing urethane resin lens having good optical homogeneity by using a specific surface active agent as an internal release agent.

It is still another object to provide a process for preparing a sulfur-containing urethane resin lens having excellent optical characteristics by using a specific surface active agent as an internal release agent.

It is a still further object to provide a process for preparing a sulfur-containing urethane resin lens industrially at a high efficiency.

It is still another object to provide a sulfur-containing urethane resin lens prepared by one of the processes as mentioned above.

Additional objects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention will be realized and attained by means of the instrumentalities and combinations, particularly pointed out in the appended claims.

To achieve the objects and in accordance with the purpose of the invention, as embodied and broadly described herein, a first object of the invention provides a process for preparing plastic lenses having a high refractive index comprising forming a mixture containing (a) one or more polyisocyanate compounds (b) one or more active hydrogen compounds selected from the group consisting of polyol compounds having no sulfur atom, polyol compounds having at least one sulfur atom, and polythiol compounds having at least one sulfur atom in addition to the sulfur atom in the mercapto group and (c) at least one internal releasing agent; casting and polymerizing the mixture to form a lens.

According to the second aspect of the present invention, there is provided a process for preparing a sulfur-containing urethane resin lens comprising pouring a mixture of polyisocyanate compound having two or more isocyanato groups, polythiol compound having two or more thiol groups, and one or more surface active agents selected from the group consisting of fluorine-containing nonionic surface active agents, silicone-containing nonionic surface active agents, alkyl quaternary ammonium salts, and acid phosphoric esters into a mold made of a glass or metal, heating and cast polymerizing the mixture.

The lenses of the invention are lightweight, excellent in impact resistance, have high surface accuracy, high refractive index, excellent optical properties, are colorless and transparent and thus are suitable for use as eyeglass lenses and camera lenses.

It has been discovered that when an internal releasing agent is added to a monomer mixture prior to casting and polymerizing the same, plastic lenses having high surface accuracy and excellent optical properties can be manufactured extremely efficiently on an industrial scale using a glass mold without any specific mold release treatment on the mold surface.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to the present preferred embodiments of the invention. Exemplary suitable internal releasing agents for use in the process of the first aspect of the invention include fluorine-containing nonionic surface active agents, silicone-containing nonionic surface active agents, alkyl quaternary ammonium salts, acid phosphoric esters, liquid paraffins, waxes, higher fatty acids and metallic salts thereof, higher fatty esters, higher fatty alcohols, bisamides, polysiloxanes and aliphatic amine ethylene oxide adducts. The most suitable internal releasing agent for any particular application can be selected based upon the combination of monomers employed, the conditions for polymerization, economy and ease of handling.

The internal releasing agents may be used alone or in the form of a mixture of two or more thereof.

The surface active agent used in the second aspect of the present invention is one or more selected from the group consisting of acid phosphoric esters, alkyl quaternary ammonium salts, fluorine-containing nonionic surface active agents and silicone-containing nonionic surface active agents. The surface active agents will be selected depending on the combination of monomers used, the polymerization conditions, and the economics or ease of handling of the surface active agent.

The fluorine-containing nonionic surface active agents, which may be used in the present invention, are compounds having a perfluoroalkyl group and a hydroxyalkyl group or a phosphoric ester group. Exemplary fluorine-containing nonionic surface active agents which are commercially available include UNIDAIN.TM.:DS-401 and DS-403 (products of Daikin Kogyo Co., Ltd.), F-TOP.TM.:EF122A, EF126 and EF301 (products of Shinakita Chemical, Co., Ltd.).

The silicone-containing nonionic surface active agents are compounds having a dimethylpolysiloxane group and a hydroxyalkyl group or a phosphoric ester group, and a typical example is Q2-120A of Dow Chemicals Co.

The alkyl quaternary ammonium salts which may be used in the present invention are known as cationic surface active agents. Exemplary suitable alkyl quaternary ammonium salts for use in the process of the invention include halogen salts, phosphates and sulfates of alkyl quaternary ammonium. Exemplary suitable chlorides thereof include trimethylcetylammonium chloride, trimethylstearylammonium chloride, dimethylethylcetylammonium chloride, triethyldodecylammonium chloride, trioctylmethylammonium chloride, trioctyldodecylammonium chlorides and diethylcyclohexyldodecylammonium chloride.

Exemplary suitable acid phosphoric esters for use in the present invention include isopropyl acid phosphate, diisopropyl acid phosphate, butyl acid phosphate, dibutyl acid phosphate, octyl acid phosphate, dioctyl acid phosphate, isodecyl acid phosphate, diisodecyl acid phosphate, tridecyl acid phosphate and bis(tridecyl) acid phosphate.

Exemplary suitable metallic salts of the higher fatty acids useful as the internal releasing agent in the present invention include zinc salts, calcium salts, magnesium salts, nickel salts, copper salts and other salts of stearic acid, oleic acid, octanoic acid, lauric acid, behenic acid and ricinoleic acid. Exemplary suitable metallic salts include zinc stearate, zinc oleate, zinc palmitate, zinc laurate, calcium stearate, calcium oleate, calcium palmitate, calcium laurate, magnesium stearate, magnesium oleate, magnesium laurate, magnesium palmitate, nickel stearate, nickel oleate, nickel palmitate, nickel laurate, copper stearate, copper oleate, copper laurate and copper palmitate.

Exemplary suitable higher fatty esters useful as the internal releasing agent in the present invention include esters of higher fatty acids such as stearic acid, oleic acid, octanoic acid, lauric acid and ricinoleic acid and alcohols such as ethylene glycol, dihydroxypropane, dihydroxybutane, neopentyl glycol and dihydroxyhexane.

In the first aspect of the invention, the amount of the internal releasing agent, which may be used alone or as a mixture of two or more, is from about 0.1 to about 10,000 ppm, preferably from about 1 to about 10,000 ppm, more preferably from about 1 to about 5,000 ppm with respect to the total weight of a monomer mixture.

When the amount of internal releasing agent is less than 0.1 ppm, mold release characteristics are poor; when it is in excess of 10,000 ppm, turbidity takes place in the prepared lenses, and each lens is prematurely separated from the mold during polymerization and the surface accuracy of the lenses deteriorates.

In the second aspect of the invention, the amount of the surface active agent to be used or the amount of a mixture of the surface active agents to be used ranges from about 1 to about 10,000 ppm, preferably from about 1 to about 5,000 ppm, based on the total amount of the polyisocyanate and the polythiol. If the amount of the surface active agent to be used is below 1 ppm, the releasability becomes extremely poor, while if the amount is greater than 10,000 ppm, release of the molded product will take place during the cast polymerization, which is not preferable because not only the surface accuracy of the lens will be deteriorated but also the produced lens will become turbid and have a white color.

Exemplary suitable polyisocyanate compounds useful in the process of the invention include aliphatic polyisocyanate compounds such as ethylene diisocyanate, trimethylene diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate, octamethylene diisocyanate, nonamethylene diisocyanate, 2,2'-dimethylpentane diisocyanate, 2,2,4-trimethylhexane diisocyanate, decamethylene diisocyanate, butene diisocyanate, 1,3-butadiene-1,4-diisocyanate, 2,4,4-trimethylhexamethylene diisocyanate, 1,6,11-undecane triisocyanate, 1,3,6-hexamethylene triisocyanate, 1,8-diisocyanato-4-isocyanatomethyloctane, 2,5,7-trimethyl-1,8-diisocyanato-5-isocyanatomethyloctane bis(isocyanatoethyl) carbonate, bis(isocyanatoethyl) ether, 1,4-butylene glycol dipropyl ether-.omega.,.omega.'-diisocyanate, lysine diisocyanatomethyl ester, lysine triisocyanate, 2-isocyanatoethyl-2,6-diisocyanato hexanoate, and 2-isocyanatopropyl-2,6-diisocyanato hexanoate.

Exemplary suitable aliphatic isocyanates having an aromatic ring include m-xylylene diisocyanate, p-xylylene diisocyanate, tetrachloro-m-xylylene diisocyanate, 1,3-bis(.alpha.,.alpha.,-dimethylisocyanatomethyl)benzene, 1,4-bis(.alpha.,.alpha.,-dimethylisocyanatomethyl)benzene, bis(isocyanatoethyl)benzene, bis(isocyanatopropyl)benzene, bis(isocyanatobutyl)benzene, .alpha.,.alpha.,.alpha.',.alpha.'-tetramethylxylylene diisocyanate, bis(isocyanatomethyl)naphthalene, bis(isocyanatomethyl) diphenylether, bis(isocyanatoethyl)phthalate, mesitylene triisocyanate, and 2,6-di(isocyanatomethyl)furan.

Exemplary suitable alicyclic isocyanates include isophorone diisocyanate, bis(isocyanatomethyl)cyclohexane, dicyclohexylmethane diisocyanate, cyclohexane diisocyanate, methylcyclohexane diisocyanate, dicyclohexyldimethylmethane diisocyanate, 2,2'-dimethyldicyclohexylmethane diisocyanate, bis(4-isocyanato-n-butylidene)pentaerythritol, dimer acid diisocyanate, 2-isocyanatomethyl-3-(3-isocyanato propyl)-5-isocyanatomethyl-bicyclo[2,2,1]-heptane, 2-isocyanatomethyl-3-(3-isocyanato propyl)-6-isocyanato methyl-bicyclo[2,2,1]-heptane, 2-isocyanato methyl-2-(3-isocyanatopropyl)-5-isocyanato methyl-bicyclo-[2,2,1]-heptane, 2-isocyanato-methyl-2-(3-isocyanatopropyl)-6-isocyanato methyl-bicyclo-[2,2,1]-heptane, 2-isocyanato methyl-3-(3-isocyanatopropyl)-5-(2-isocyanato ethyl)-bicyclo-[2,2,1]heptane, 2-isocyanatomethyl-3-(3-isocyanatopropyl)-6-(2-isocyanato ethyl)-bicyclo-[2,2,1]-heptane, 2-isocyanatomethyl-2-(3-isocyanatopropyl)-5-(2-isocyanatoethyl)-bicyclo-[2,2,1]-heptane, and 2-isocyanatomethyl-2-(3-isocyanatopropyl)-6-(2-isocyanatoethyl)-bicyclo-[2,2,1]heptane.

Exemplary suitable aromatic isocyanates include phenylene diisocyanate, tolylene diisocyanate, ethylphenylene diisocyanate, isopropylphenylene diisocyanate, dimethylphenylene diisocyanate, diethylphenylene diisocyanate, diisopropylphenylene diisocyanate, trimethylbenzene triisocyanate, benzene triisocyanate, naphthalene diisocyanate, methylnaphthalene diisocyanate, biphenyl diisocyanate, tolidine isocyanate, 4,4'-diphenylmethane diisocyanate (MDI), 3,3'-dimethyldiphenylmethane-4,4'-diisocyanate, dibenzyl-4,4'-diisocyanate, bis(isocyanatophenyl)ethylene, 3,3'-dimethoxybiphenyl-4,4'-diisocyanate, triphenylmethane triisocyanate, polymeric MDI, naphthalene triisocyanate, diphenylmethane-2,4,4'-triisocyanate, 3-methyldiphenylmethane-4,6,4'-triisocyanate, 4-methyldiphenylmethane-3,5,2',4',6'-pentaisocyanate, phenylisocyanatomethyl isocyanate, phenylisocyanatoethyl isocyanate, tetrahydronaphthalene diisocyanate, hexahydrobenzene diisocyanate, hexahydrodiphenylmethane-4,4'-diisocyanate, diphenyl ether diisocyanate, ethylene glycol diphenyl ether diisocyanate, 1,3-propylene glycol diphenyl ether diisocyanate, benzophenone diisocyanate, diethylene glycol diphenyl ether diisocyanate, dibenzofuran diisocyanate, carbazole diisocyanate, ethylcarbazole diisocyanate, and dichlorocarbazole diisocyanate. In addition, halogen-substituted compounds such as chlorine-substituted compounds, and bromine-substituted compounds, alkyl-substituted compounds, alkoxy-substituted compounds, and nitro-substituted compounds of these polyisocyanates, prepolymer type modified compounds of these polyisocyanates with polyhydric alcohols, carbodiimide-modified compounds of these polyisocyanates, urea-modified compounds of these polyisocyanates, biuret-modified compounds of these polyisocyanates, dimerized products of these polyisocyanates, and trimerized products of these polyisocyanates can also be used. These may be used alone or in a mixture of two or more polyisocyanate compounds.

Exemplary polyol compounds that contain no sulfur atom suitable for use in the process of the first aspect of the invention include ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, neopentyl glycol, glycerin, trimethylolethane, trimethylolpropane, butanetriol, 1,2-methyl glycoside, pentaerythritol, dipentaerythritol, tripentaerythritol, sorbitol, erythritol, threitol, ribitol, arabinitol, xylitol, allitol, mannitol, dorcitol, iditol, glycol, inositol, hexanetriol, triglycerol, diglycerol, triethylene glycol, polyethylene glycol, tris(2-hydroxyethyl) isocyanurate, cyclobutanediol, cyclopentanediol, cyclohexanediol, cycloheptanediol, cyclooctanediol, cyclohexane dimethanol, hydroxypropylcyclohexanol, tricyclo(5,2,1,0.sup.2.6)decane dimethanol, bicyclo(4,3,0)nonanediol, dicyclohexanediol, tricyclo(5,3,1,1)dodecanediol, bicyclo(4,3,0)nonane dimethanol, tricyclo(5,3,1,1)dodecane diethanol, hydroxypropyltricyclo-(5,3,1,1)dodecanol, spiro(3,4)octanediol, butylcyclohexanediol, 1,1'-bicyclohexylidenediol, cyclohexanetriol, maltitol, lactitol, dihydroxynaphthalene, trihydroxynaphthalene, tetrahydroxynaphthalene, dihydroxybenzene, benzenetriol, biphenyltetraol, pyrogallol, (hydroxynaphthyl)pyrogallol, trihydroxyphenanthrene, bisphenol A, bisphenol F, xylylene glycol, di(2-hydroxyethoxy)benzene, bisphenol A-bis-(2-hydroxyethyl ether), tetrabromobisphenol A, tetrabromobisphenol A-bis(2-hydroxyethylether), dibromoneopentyl glycol and epoxy resin; condensation reaction products of these polyols and organic polybasic acids such as oxalic acid, glutamic acid, adipic acid, acetic acid, propionic acid, cyclohexanecarboxylic acid, .beta.-oxycyclohexanepropionic acid, dimer acid, phthalic acid, isophthalic acid, salicylic acid, 3-bromopropionic acid, 2-bromoglycolic acid, dicarboxycyclohexane, pyromellitic acid, butanetetracarboxylic acid and bromophthalic acid; addition reaction products of the polyol compounds and alkylene oxides such as ethylene oxide and propylene oxide; and addition reaction products of alkylene polyamines and alkylene oxides such as ethylene oxide and propylene oxide.

Furthermore, halogen-substituted compounds such as chlorine-substituted and bromine-substituted compounds of the polyol compounds may also be employed.

Exemplary polyol compounds containing at least one sulfur atom suitable for use in the process of the first aspect of the invention include bis[4-(hydroxyethoxy)phenyl] sulfide, bis[4-(2hydroxypropoxy) phenyl] sulfide, bis-[4-(2,3-dihydroxypropoxy) phenyl] sulfide, bis-[4,(4-hydroxycyclohexyloxy)] sulfide, bis-[2-methyl-4-(hydroxyethoxy)-6-butylphenyl] sulfide and compounds prepared by adding ethylene oxide and/or propylene oxide to these sulfides in a ratio of three or less molecules of the oxide per hydroxyl group of each sulfide on the average, di-(2-hydroxyethyl) sulfide, 1,2-bis-(2-hydroxyethylmercapto)ethane, bis-(2-hydroxyethyl) disulfide, 1,4-dithian-2,5-diol, bis(2,3-dihydroxypropyl) sulfide, tetrakis(4-hydroxy-2-thiabutyl)methane, bis(4-hydroxyphenyl) sulfone (trade name Bisphenol S), tetrabromobisphenol S, tetramethylbisphenol S, 4,4'-thiobis(6-tertbutyl-3-methylphenol) and 1,3-bis(2-hydroxyethylthioethyl)cyclohexane. Halogen-substituted compounds such as chlorine-substituted and bromine-substituted compounds of the polyol compounds may also be employed.

Exemplary suitable polythiol compounds having at least one sulfur atom in addition to the sulfur atom in mercapto group useful in the process of the invention include aromatic polythiol compounds such as 1,2-bis(mercaptomethylthio)benzene, 1,3-bis(mercaptomethylthio)benzene, 1,4-bis(mercaptomethylthio)benzene, 1,2-bis(mercaptoethylthio)benzene, 1,3-bis(mercaptoethylthio)benzene, 1,4-bis(mercaptoethylthio)benzene, 1,2,3-tris(mercaptomethylthio)benzene, 1,2,4-tris(mercaptomethylthio)benzene, 1,3,5-tris(mercaptomethylthio)benzene, 1,2,3-tris(mercaptoethylthio)benzene, 1,2,4-tris(mercaptomethylthio)benzene, 1,3,5-tris(mercaptoethylthio)benzene, 1,2,3,4-tetrakis-(mercaptomethylthio) benzene, 1,2,3,5-tetrakis (mercaptomethylthio)benzene, 1,2,4,5-tetrakis (mercaptomethyl thio)benzene, 1,2,3,4-tetrakis (mercaptoethylthio)benzene, 1,2,3,5-tetrakis (mercaptoethylthio)benzene, 1,2,4,5-tetrakis (mercaptoethylthio)benzene and their nucleus-alkylated compounds; aliphatic polythiol compounds such as bis(mercaptomethyl) sulfide, bis (mercaptoethyl) sulfide, bis (mercaptopropyl) sulfide, bis (mercaptomethylthio)methane, bis (2-mercaptoethylthio)methane, bis (3-mercaptopropylthio)methane, 1,2-bis(mercaptomethylthio)ethane, 1,2-bis (mercaptoethylthio)ethane, 1,2-bis(3-mercaptopropylthio)ethane, 1,3-bis(mercaptomethylthio)propane, 1,3-bis(2-mercaptoethylthio)propane, 1,3-bis(3-mercaptopropylthio)propane, 1,2,3-tris (mercaptomethylthio)propane, 1,2,3-tris(2-mercaptoethylthio) propane, 1,2,3-tris(3-mercaptopropylthio) propane, tetrakis (mercaptomethylthiomethyl) methane, tetrakis (2-mercaptoethylthiomethyl)methane, tetrakis (3-mercaptopropylthiomethyl)methane, bis (2,3 -dimercaptopropyl) sulfide, 2,5-dimercapto-1,4-dithiane, bis (mercaptomethyl)disulfide, bis(mercaptoethyl) disulfide, bis(mercaptopropyl)disulfide, and esters of these compounds and thioglycolic acid or mercaptopropionic acid, hydroxymethyl sulfide bis(2-mercapto acetate), hydroxymethyl sulfide bis(3-mercapto propionate), hydroxyethyl sulfide bis (2-mercapto acetate), hydroxyethyl sulfide bis(3-mercapto propionate), hydroxypropyl sulfide bis(2-mercapto acetate), hydroxypropyl sulfide bis (3-mercapto propionate), hydroxymethyl disulfide bis(2-mercapto acetate), hydroxymethyl disulfide bis(3mercapto propionate), hydroxyethyl disulfide bis (2-mercapto acetate), hydroxyethyl disulfide bis(3-mercaptopropionate), hydroxypropyl disulfide bis(2-mercaptoacetate), hydroxypropyl disulfide bis(3-mercaptopropionate), 2-mercapto ethyl ether bis(2-mercapto acetate), 2-mercapto ethyl ether bis(3-mercapto propionate), 1,4-dithian-2,5-diolbis(2-mercapto acetate), 1,4-dithian-2,5-diolbis(3-mercapto propionate), thiodiglycolic acid bis(2-mercapto ethyl ester), thiodipropionic acid bis(2-mercapto ethyl ester), 4,4-thiodibutylic acid bis(2-mercapto ethyl ester), dithiodiglycolic acid bis(2-mercapto ethyl ester), dithiodipropionic acid bis(2-mercapto ethyl ester), 4,4-dithiodibutylic acid bis(2-mercapto ethyl ester), thiodiglycolic acid bis(2,3-dimercapto propyl ester), thiodipropionic acid bis(2,3-dimercapto propyl ester), dithioglycolic acid bis(2,3-dimercapto propyl ester) and dithiopropionic acid bis(2,3-dimercapto propyl ester) except bis(2-mercaptoethyl) sulfide; and heterocyclic compounds such as 3,4-thiophenedithiol, bismuthiol and 2,5-dimercapto-1,3,4-thiadiazole. In addition, halogen-substituted compounds such as chlorine-substituted and bromine-substituted compounds may be employed.

The active hydrogen compounds may be used alone or in the form of a mixture of two or more thereof.

In the first aspect of the invention, the molar ratio of the polyisocyanate compound to the active hydrogen compound is from about 0.5 to about 3.0, preferably from about 0.5 to about 1.5 of functional isocyanate group per mole of functional (SH+OH) group.

In the second aspect of the invention, at least one polythiol having two or more thiol groups is used.

Examples of polythiols having two or more thiol groups include aliphatic polythiols such as methanedithiol, 1,2-ethanedithiol, 1,1-propanedithiol, 1,2-propanedithiol, 1,3-propanedithiol, 1,4butanedithiol, 2,2-propanedithiol, 1,6-hexanedithiol, 1,2,3-propanetrithiol, 1,2,2-dimethylpropane-1,3-dithiol, 3,4-dimethoxybutane-1,2-dithiol, thiomalic acid bis(2-mercaptoethyl ester), 2,3-dimercaptosuccinic acid (2-mercaptoethyl ester), 2,3-dimercapto-1-propanol (2-mercaptoacetate), 2,3-dimercapto-1-propanol (3-mercaptopropionate), diethylene glycol bis(2-mercaptoacetate), diethylene glycol bis(3-mercaptopropionate), 1,2-dimercaptopropylmethyl ether, 2,3-dimercaptopropylmethyl ether, 2,2-bis(mercaptomethyl)-1,3-propanedithiol, di(2mercaptoethyl)ether, ethylene glycol bis(2-mercaptoacetate), ethylene glycol bis(3-mercaptopropionate), trimethylolpropane tris(2-mercaptoacetate), trimethylolpropane tris(3-mercaptopropionate), pentaerythritol tetrakis(2-mercaptoacetate), pentaerythritol tetrakis(3-mercaptopropionate), dipentaerythritol hexakis(2-mercaptoacetate), and dipentaerythritol hexakis(3-mercaptopropionate), halogen-substituted compounds of these polythiols such as chlorine-substituted compounds and bromine-substituted compounds of these polythiols, alicyclic polythiols such as 1,1-cyclohexanedithiol, 1,2-cyclohexanedithiol, 2-methylcyclohexane-2,3-dithiol, bicyclo[2,2,1]hepta-exo-cis-2,3-dithiol, 1,1-bis(mercaptomethyl)cyclohexane, and halogen-substituted compounds of these polythiols such as chlorine-substituted compounds and bromine-substituted compounds of these polythiols, polythiols having an aromatic ring such as 1,2-dimercaptobenzene,

1,3-dimercaptobenzene, 1,4-dimercaptobenzene, 1,2-bis(mercaptomethyl)benzene, 1,3-bis(mercaptomethyl)benzene, 1,4-bis(mercaptomethyl)benzene, 1,2-bis(mercaptoethyl)benzene, 1,3-bis(mercaptoethyl)benzene, 1,4-bis(mercaptoethyl)benzene, 1,2-bis(mercaptomethyleneoxy)benzene, 1,3-bis(mercaptomethyleneoxy)benzene, 1,4-bis(mercaptomethyleneoxy)benzene, 1,2-bis(mercaptoethyleneoxy)benzen, 1,3-bis(mercaptoethyleneoxy)benzene, 1,4-bis(mercaptoethyleneoxy)benzene, 1,2,3-trimercaptobenzene, 1,2,4-trimercaptobenzene, 1,3,5-trimercaptobenzene, 1,2,3-tris(mercaptomethyl)benzene, 1,2,4-tris-(mercaptomethyl)benzene, 1,3,5-tris(mercaptomethyl)benzene, 1,2,3-tris(mercaptoethyl)benzene, 1,2,4-tris(mercaptoethyl)benzene, 1,3,5-tris(mercaptoethyl)benzene, 1,3,5-tris(3-mercaptopropyl) isocyanurate, 1,2,3-tris(mercaptomethyleneoxy)benzene, 1,2,4-tris(mercaptomethyleneoxy)benzene, 1,3,5-tris(mercaptomethyleneoxy)benzene, 1,2,3-tris(mercaptoethyleneoxy)benzene, 1,2,4-tris(mercaptoethyleneoxy)benzene, 1,3,5-tris(mercaptoethyleneoxy)benzene, 1,2,3,4-tetramercaptobenzene, 1,2,3,5-tetramercaptobenzene, 1,2,4,5-tetramercaptobenzene, 1,2,3,4-tetrakis (mercaptomethyl)benzene, 1,2,3,5-tetrakis (mercaptomethyl)benzene, 1,2,4,5-tetrakis (mercaptomethyl)benzene, 1,2,3,4-tetrakis (mercaptoethyl)benzene, 1,2,3,5-tetrakis (mercaptoethyl)benzene, 1,2,4,5-tetrakis (mercaptoethyl)benzene, 1,2,3,4-tetrakis (mercaptomethyleneoxy)benzene, 1,2,3,5-tetrakis (mercaptomethyleneoxy)benzene, 1,2,4,5-tetrakis (mercaptomethyleneoxy)benzene, 1,2,3,4-tetrakis (mercaptoethyleneoxy)benzene, 1,2,3,5-tetrakis (mercaptoethyleneoxy)benzene, 1,2,4,5-tetrakis (mercaptoethyleneoxy)benzene, 2,2'-dimercaptobiphenyl, 4,4'-dimercaptobiphenyl, 4,4'-dimercaptobibenzyl, 2,5-toluenedithiol, 3,4-toluenedithiol, o-xylylenedithiol, m-xylylenedithiol, p-xylylenedithiol, 1,4-naphthalenedithiol, 1,5-naphthalenedithiol, 2,6-naphthalenedithiol, 2,7-napthalenedithiol, 4-methyl-l,2-dimercaptobenzene, 2,4-dimethylbenzene-1,3-dithiol, 4,5-dimethylbenzene-1,3-dithiol, 9,10-anthracenedimethanethiol, 1,3-di(p-methoxyphenyl)propane-2,2-dithiol, 1,3-diphenylpropane-2,2-dithiol, phenylmethane-1,1-dithiol, and 2,4-di(p-mercaptophenyl)pentane, halogen-substituted aromatic polythiols such as chlorine-substituted products and bromine-substituted products for example 3,6-dichloro-1,2-dimercaptobenzene, 2,5-dichlorobenzene-1,3-dithiol, 1,3-di(p-chlorophenyl)propane-2,2-dithiol, 3,4,5-tribromo-1,2-dimercaptobenzene, 3,4,5,6-tetrachloro-1,2-dimercaptobenzene, and 2,3,4,6-tetrachloro-1,5-bis(mercaptomethyl)benzene, and polythiols having a heterocyclic ring such as 1,3,5-tris(3-mercaptopropyl)isocyanurate, 2-methylamino-4,6-dithiol-sym-triazine, 2-ethylamino-4,6-dithiol-sym-triazine, 2-amino-4, 6-dithiol-sym-triazine, 2-morpholino-4,6-dithiol-sym-triazine, 2-cyclohexylamino-4,6-dithiol-sym-triazine, 2-methoxy-4,6-dithiol-sym-triazine, 2-phenoxy-4,6-dithiol-sym-triazine, 2-thiobenzeneoxy-4,6-dithiol-symtriazine, and 2-thiobutyloxy-4,6-dithiol-sym-triazine, and halogen-substituted compounds of these polythiol such as chlorine-substituted compounds and bromine-substituted compounds of these polythiols.

These compounds may be used alone or as a mixture of two or more of them.

In the second aspect of the invention, the ratio between the polyisocyanate having two or more isocyanato groups and the polythiol having two or more thiol groups is such that an NCO/SH equivalent ratio is generally in a range of from about 0.5/1.0 to about 3.0/1.0, preferably from about 0.5/1.0 to about 1.5/1.0.

In the plastic lens of the first aspect of the present invention, a urethane resin or thiocarbamic acid S-alkyl ester resin is used as a raw material, and therefore in the plastic lens a urethane bond exists between an isocyanate group and a hydroxyl group, or a thiocarbamic acid S-alkyl ester bond exists between the isocyanate group and a mercapto group. However, the plastic lens of the present case may also contain an allophanate bond, a urea bond, a biuret bond. For example, it may be desirable to further react the isocyanate group with the urethane bond or the thiocarbamic acid S-alkyl ester bond to increase the crosslink density. Such a reaction may be carried out at a temperature of at least 100.degree. C. and the isocyanate component should be used in an excess amount. Alternatively, an amine compound or the like may also be used to produce a urea bond or biuret bond. When the isocyanate compound is reacted with a compound other than the hydroxyl compound or mercapto compound, attention should be paid to coloring.

Furthermore, in the present invention, various additives may be added to the above-mentioned raw materials. Exemplary suitable additives include a chain extender, a crosslinking agent, a light stabilizer, an ultraviolet absorber, an antioxidant, an oil-soluble dye and a filler.

The reaction rate may be adjusted to a desired level by adding a known reaction catalyst useful in the manufacture of a polyurethane or thiocarbamic acid S-alkyl ester.

The plastic lens of the present invention can be prepared by cast polymerization. One or more of the polyisocyanate compounds and one or more of the active hydrogen compounds are mixed to form a mixture. At least one internal releasing agent is added to the mixture. The resulting mixture is then poured into a mold, followed by the polymerization.

Polymerization is usually carried out at from about -50.degree. C. to about 200.degree. C. and in from about 0.5 to about 72 hours, depending upon the types of monomers and mold releasing agent employed.

The thus polymerized lenses may be subjected to an annealing treatment, if necessary.

In the second aspect of the present invention, there are mixed polyisocyanate having two or more isocyanato groups, polythiol having two or more thiol groups and a surface active agent. If necessary, catalyst and other additives are further mixed therewith.

Furthermore, in the case that there is a possibility that air or the like dissolves in the raw materials during transportation or preparation, the dissolved gas is fully removed from the mixture when needed.

Afterward, the uniformed mixture is cast into a mold and then polymerized.

The mold comprises a combination of a resin gasket and a metal or glass mold, and the material of the mold is preferably glass in view, for example, of the operability, productivity, and the surface accuracy of the lens that will be obtained.

Although the polymerization temperature and the polymerization time are selected suitably depending on the type of monomers, the release agent, the additives such as the catalyst, and the shape and the thickness of the lens to be obtained, polymerization is started at a low temperature, then the temperature is raised, and the polymerization is completed within 3 to 24 hours, preferably at a temperature of from about 30.degree. C. to about 120.degree. C.

The plastic lenses of the present invention have high surface accuracy and excellent optical properties, are lightweight and excellent in impact resistance, and are suitable for lenses of glasses and cameras.

Moreover, the lenses of the present invention can be subjected to physical and chemical treatments such as a surface abrasion treatment, an antistatic treatment, a hard coat treatment, a non-refractive coat treatment, a coloring treatment and a dimming treatment for the prevention of reflection, the enhancement of hardness, the improvement of abrasion resistance and chemical resistance, fog resistance, the supply of fashionability, and the like.

The invention will be further explained by the following examples which are intended to be purely exemplary of the invention. Of the examples, Examples 1-32 and Comparative Examples 1-24 relate to the first aspect of the present invention and Examples 33-57 and Comparative Examples 25-45 relate to the second aspect of the present invention. The refractive index, Abbe's number, mold release characteristics and appearance were evaluated by the following tests in connection with examples relating to the first aspect of the invention:

Refractive index and Abbe's number: Measured at 20.degree. C. by the use of a Pulflich refractometer.

Mold release characteristics: When a polymerized lens was released from a mold without resistance, the mold release characteristics were denoted by "0" and when a part or all of the lens was not released therefrom, they were denoted by "X" and separated by means of driving in a Teflon.TM. wedge between the lens and the mold.

Appearance: Evaluated by visual observation.

Among the performance tests for the lenses and test pieces, releasability, strain, surface accuracy, and transparency were evaluated by the following methods in connection with examples relating to the second aspect of the invention:

Releasability: When the release was easy after the completion of the polymerization, it was denoted "0", whereas when a part or all of the product was not released after the completion of the polymerization, it was denoted "X".

Strain: The presence of strain was observed by a strain meter, and when there was not strain, it was denoted "0" whereas when there was strain, it was denoted "X".

Surface accuracy: The surface accuracy was observed visually, and when it was good, it was denoted "0", whereas when it was bad, it was denoted "X".

Transparency: The total ray transmittance was determined according to JIS K 7105-1981, and when its value was 85% over and when it was transparent throughout under a slide projector lamp, it was denoted "0" and other cases were denoted "X".

EXAMPLE 1

50 g (0.30 mol) of hexamethylene diisocyanate, 27 g (0.30 mol) of 1,4-butanediol and 0.08 g of dodecanol acid phosphate were mixed. The resulting mixture was then poured into a mold composed of a glass mold and a gasket. Then the mold was gradually heated from room temperature to 120.degree. C. for 24 hours to complete the polymerization. After polymerization, the lens was easily released from the mold. The lens had high surface accuracy and was colorless. Moreover, it had a refractive index n.sup.20 of 1.50 and an Abbe's number .upsilon..sup.20 of 55.

EXAMPLES 2 TO 32

Following the procedure of Example 1, lenses were prepared in composition ratios shown in Table 1. The results of performance tests are set forth in Table 1.

COMPARATIVE EXAMPLES 1 TO 24

Following the procedure of Example 1 with the exception that the undermentioned mold treatments were carried out, lenses were prepared in composition ratios shown in Table 2. The results of performance tests are set forth in Table 2.

(1) No treatment . . . A glass mold was used without any release treatment. (2) External release treatment . . . External mold releasing agent YSR-6209.TM. (product of Toshiba Silicon Co.) was applied and baked on the inner surface of a glass mold. (3) Reuse of external release treatment . . . The glass mold obtained by the external release treatment was once employed for the polymerization and then used again without any further treatment. (4) Use of PP mold . . . A polypropylene mold was prepared by injection molding and used in place of the glass mold without any surface treatment. TABLE 1__________________________________________________________________________ Active Internal Release Refrac-Polyiso- Hydrogen Releas- Charac- Appear- tive Abbe'scyanate Compound ing Agent eristics ance Index Number__________________________________________________________________________Example 2 Dicyclo- 1,4-Butanediol UNIDAIN .largecircle. High 1.52 51 hexyl- 0.30 mol DS-401 surface methane 200 ppm accuracy, diiso- Trans- cyanate parent 0.30 molExample 3 Hexa- Trimethylol- Trimethyl- .largecircle. High 1.51 54 methylene propane cetyl- surface diiso- 0.20 mol ammonium accuracy, cyanate chloride Trans- 0.30 mol 500 ppm parentExample 4 Dicyclo- Bisphenol A Dilso- .largecircle. High 1.54 42 methane 0.30 mol propyl- surface diiso- Trimethylol- acid accuracy, cyanate propane phosphate Trans- 0.60 mol 0.20 mol 1000 ppm parentExample 5 m-Xylylene 1,4-Cyclohex- F-TOP .largecircle. High 1.57 36 diiso- anedimethanol EF301 surface cyanate 0.15 mol 150 ppm accuracy, 0.60 mol Trimethylol Trans- propane parent 0.10 molExample 6 Isophorone Bisphenol A Octylacid .largecircle. High 1.54 44 diiso- 0.30 mol phosphate surface cyanate Trimethylol 500 ppm accuracy, 0.60 mol propane Trans- 0.20 mol parentExample 7 Dicyclo- 1,4-Cyclohex- Octylacid .largecircle. High 1.53 50 hexyl- anedimethanol phosphate surface methane 0.30 mol 800 ppm accuracy, diiso- Trimethylol- Trans- cyanate propane parent 0.60 mol 0.20 molExample 8 Tolylene 1,4-Cyclo- Octylacid .largecircle. High 1.58 35 diiso- hexanedi- phosphate surface cyanate methanol 800 ppm accuracy, 0.60 mol 0.30 mol Trans- Trimethylol- parent propane 0.20 molExample 9 m-Xylylene Tetrabromo- UNIDAIN .largecircle. High 1.60 33 diiso- bisphenol A DS-401 surface cyanate 0.10 mol 250 ppm accuracy, 0.20 mol Trimethylol- Trans- propane parent 0.06 molExample 10 m-Xylylene 2-Hydroxyethyl UNIDAIN .largecircle. High 1.59 38 diiso- sulfide DS-401 surface cyanate 0.05 mol 1000 ppm accuracy 0.05 mol Trans- parentExample 11 Hexa- Tetrakis- UNIDAIN .largecircle. High 1.56 45 methylene (4-hydroxy- DS-401 surface diios- 2-thiabutyl) 200 ppm accuracy cyanate methane Trans- 0.08 mol 0.04 mol parentExample 12 m-Xylylene Tetrakis- Diiso- .largecircle. High 1.61 37 diiso- (4-hydroxy- propylacid surface cyanate 2-thiabutyl) phosphate accuracy 0.08 mol methane 500 ppm Trans- 0.04 mol parentExample 13 Lysine Tetrakis- Trimethyl- .largecircle. High 1.57 44 triiso- (4-hydroxy- cetyl- surface cyanate 2-thiabutyl) ammonium accuracy 0.04 mol methane chloride Trans- 0.03 mol 1000 ppm parentExample 14 m-Xylylene 1,2-Bis-(2- Tridecyl .largecircle. High 1.60 38 diiso- hydroxyethyl- acid surface cyanate mercapto)- phosphate accuracy 0.08 mol ethane 10000 ppm Trans- 0.08 mol parentExample 15 Hexa- 2-Hydoxyethyl F-TOP .largecircle. High 1.56 44 methylene sulfide EF-122A surface diiso- 0.08 mol 150 ppm accuracry, cyanate Trans- 0.08 mol parentExample 16 Tetra- 2-Hydoxyethyl Diiso- .largecircle. High 1.61 37 chloro- sulfide propylacid surface xylylene 0.08 mol phosphate accuracry, diiso- 800 ppm Trans- cyanate parent 0.08 molExample 17 m-Xylylene Bis[4- Trimethyl- .largecircle. High 1.61 34 diiso- (hydroxy- cetyl- surface cyanate ethoxyl)- ammonium accuracry, 0.08 mol phenyl] chloride Trans- sulfide 200 ppm parent 0.08 molExample 18 4,4'-Di- Bis[4-(hydroxy- Trimethyl- .largecircle. High 1.62 31 phenyl- propoxy)phenyl] cetyl- surface methane sulfide ammonium accuracry, diiso- 0.03 mol chloride Trans- 0.09 Bis[4-(2,3- 200 ppm parent dihydroxypro- poxy)phenyl sulfide 0.03 molExample 19 m-Xylylene Tetrakis(2- Isopropyl .largecircle. High 1.66 33 diiso- mercaptoethyl acid surface cyanate thiomethyl) phosphate accuracy 0.10 mol methane 1000 ppm Trans- 0.05 mol parentExample 20 m-Xylylene Hydroxy- Trimethyl- .largecircle. High 1.60 38 diiso- methyl cetyl- surface cyanate sulfide ammonium accuracy 0.10 mol bis(2-mercapto chloride Trans- acetate) 150 ppm parent 0.10 molExample 21 m-Xylylene 1,2-Di(2- Tridecyl .largecircle. High 1.64 36 diiso- mercapto- acid surface cyanate ethylthio) phosphate accuracy 0.10 mol ethane 500 ppm Trans- 0.10 mol parentExample 22 m-Xylylene 1,2-Di(2- Trioctyl- .largecircle. High 1.64 36 diiso- mercapto- methyl- surface cyanate ethylthio) ammonium accuracy 0.10 mol ethane chloride Trans- 0.10 mol 500 ppm parentExample 23 Hexa- Tetrakis(2- UNIDAIN .largecircle. High 1.62 42 methylene mercapto- DS-401 surface diiso- ethylthio- (Daikin) accuracy cyanate methyl)methane 250 ppm Trans- 0.10 mol 0.05 mol parentExample 24 Isophorone Tetrakis(2- UNIDAIN .largecircle. High 1.60 40 diiso- mercapto- DS-401 surface cyanate ethylthio- (Daikin) accuracry, 0.10 mol methyl)methane 100 ppm Trans- parentExample 25 Tetra- Tetrakis(2- F-TOP .largecircle. High 1.68 33 chloro- mercapto- EH-126 surface xylylene ethylthio- 500 ppm accuracry, diiso- methyl)methane Trans- cyanate parent 0.10 molExample 26 Tetra- Dithiodi- Isopropyl- .largecircle. High 1.66 33 chloro- glycolic acid surface xylylene acid bis(2- phosphate accuracry, diiso- mercapto- 800 ppm Trans- cyanate butyl ester) parent 0.10 mol 0.10 molExample 27 Tolylene Tetrakis(2- Isopropyl- .largecircle. High 1.68 30 diiso- mercaptoethyl- acid surface cyanate thiomethyl)- phosphate accuracry, 0.10 mol methane 800 ppm Trans- 0.05 mol parentExample 28 m-Xylylene 1,2-Di(2- Isopropyl .largecircle. High 1.65 35 diiso- mercapto- acid surface cyanate ethylthio)- phosphate accuracy, 0.10 mol ethane 500 ppm Trans- 0.02 mol parent Tetrakis(2- mercaptoethyl- thiomethyl)- methane 0.04 molExample 29 m-Xylylene Trimethylol- UNIDAIN .largecircle. High 1.56 38 diiso- propane DS-401 surface cyanate 0.04 mol 1000 ppm accuracy, 0.10 mol 2-Hydroxy- Trans- ethyl sulfide parent 0.04 molExample 30 Hexa- Trimethylol- F-TOP .largecircle. High 1.57 42 methylene propane EF-122A surface diiso- 0.04 mol 200 ppm accuracy, cyanate 1,2-Di(2-mer- Trans- 0.01 mol captoethyl- parent thio)ethane 0.04 molExample 31 Hexa- 2-Hydroxyethyl Diisopropyl .largecircle. High 1.56 41 methylene sulfide acid surface diiso- 0.04 mol phosphate accuracy, cyanate 1,2-Di(2-mer- 500 ppm Trans- 0.01 mol captoethyl- parent thio)ethane 0.04 molExample 32 m-Xylylene Tetrakis(2- Isopropyl .largecircle. High 1.65 34 diiso- mercapto- acid surface cyanate ethylthio- phosphate accuracy, 0.08 mol methyl)methane 800 ppm Trans- Trilendiiso 0.04 mol parent cyanate 0.02 mol__________________________________________________________________________ TABLE 2__________________________________________________________________________ Active Mold Release Refrac-Polyiso- Hydrogen Treat- Charac- Appear- tive Abbe'scyanate Compound ment teristics ance Index Number__________________________________________________________________________Comp. Hexa- 1,4-Butanediol No X -- -- --Ex. 1 methylene 0.30 mol treat- diiso- ment cyanate 0.30 molComp. Hexa- 1,4-Butanediol External .largecircle. Uneven 1.50 55Ex. 2 methylene 0.30 mol release surface, diiso- treat- Trans- cyanate ment parent 0.30 molComp. Hexa- 1,4-Butanediol Reuse of X -- -- --Ex. 3 methylene 0.30 mol external diiso- release cyanate treatment 0.30 mol (mold used in Comp. Ex. 2)Comp. Hexa- 1,4-Butanediol Use of .largecircle. Bad 1.50 55Ex. 4 methylene 0.30 mol PP mold surface diiso- accuracy, cyanate Trans- 0.30 mol parentComp. Dicyclo- 1,4-Butanediol No X -- -- --Ex. 5 hexyl- 0.30 mol treat- methane ment diiso- cyanate 0.30 molComp. Dicyclo- 1,4-Butanediol External .largecircle. Uneven 1.52 51Ex. 6 hexyl- 0.30 mol release surface, methane treat- Trans- diiso- ment parent cyanate 0.30 molComp. Dicyclo- 1,4-Butanediol Reuse of X -- -- --Ex. 7 hexyl- 0.30 mol external methane release diiso- treatment cyanate (mold used 0.30 mol in Comp. Ex. 6)Comp. Dicyclo- 1,4-Cyclo- Use of .largecircle. Bad 1.53 50Ex. 8 hexyl- hexanedi- PP mol surface methane methanol accuracy, diiso- 0.15 mol Trans- cyanate Trimethylol- parent 0.30 mol propane 0.10 molComp. Xylylene 2-Hydroxyethyl No X -- -- --Ex. 9 diiso- sulfide treat- cyanate 0.05 mol ment 0.05 molComp. Xylylene 2-Hydroxyethyl External .largecircle. Uneven 1.59 38Ex. 10 diiso- sulfide release surface, cyanate 0.05 mol treat- Trans- 0.05 mol ment parentComp. Xylylene 2-Hydroxyethyl Reuse of X -- -- --Ex. 11 diiso- sulfide external cyanate 0.05 mol release 0.05 mol treatment (mold used in Comp. Ex. 2)Comp. Xylylene 2-Hydroxyethyl Use of .largecircle. Bad 1.59 38Ex. 12 diiso- sulfide PP mold surface cyanate 0.05 mol accuracy, 0.05 mol Trans- parentComp. Lysine Tetrakis-(4- No X -- -- --Ex. 13 triiso- hydroxy-2- treat- cyanate thiabutyl) ment 0.04 mol methane 0.03 molComp. Lysine Tetrakis-(4- External .largecircle. Uneven 1.57 44Ex. 14 triiso- hydroxy-2- release surface, cyanate thiabutyl) treat- Trans- 0.04 mol methane ment parent 0.03 molComp. Lysine Tetrakis-(4- Reuse of X -- -- --Ex. 15 triiso- hydroxy-2- external cyanate thiabutyl) release 0.04 mol methane treatment 0.03 mol (mold used in Comp. Ex. 6)Comp. Xylylene Tetrakis-(4- Use of .largecircle. Bad 1.61 37Ex. 16 diiso- hydroxy-2- PP mold surface cyanate thiabutyl) accuracy, 0.06 mol methane Trans- 0.03 mol parentComp. Xylylene Tetrakis(2- No X -- -- --Ex. 17 diiso- mercaptoethyl- treat- cyanate thiomethyl)- ment 0.10 mol methane 0.05 molComp. Xylylene Tetrakis(2- External .largecircle. Uneven 1.66 33Ex. 18 diiso- mercaptoethyl- release surface, cyanate thiomethyl)- treat- Trans- 0.10 mol methane ment parent 0.05 molComp. Xylylene Tetrakis(2- Reuse of X -- -- --Ex. 19 diiso- mercaptoethyl- external cyanate thiomethyl)- release 0.10 mol methane treatment 0.05 mol (mold used in Comp. Ex. 2)Comp. Xylylene Tetrakis(2- Use of .largecircle. Bad 1.66 33Ex. 20 diiso- mercaptoethyl- PP mold surface cyanate thiomethyl)- accuracy, 0.10 mol methane Trans- 0.05 mol parentComp. Hexa- Tetrakis(2- No X -- -- --Ex. 21 methylene mercaptoethyl- treat- diiso- thiomethyl)- ment cyanate methane 0.10 mol 0.05 molComp. Hexa- Tetrakis(2- External .largecircle. Uneven 1.62 42Ex. 22 methylene mercaptoethyl- release surface, diiso- thiomethyl)- treat- Trans- cyanate methane ment parent 0.10 mol 0.05 molComp. Hexa- Tetrakis(2- Reuse of X -- -- --Ex. 23 methylene mercaptoethyl- external diiso- thiomethyl)- release cyanate methane treatment 0.10 mol 0.05 mol (mold used in Comp. Ex. 6)Comp. Tetra- Dithiodiglycolic Use of .largecircle. Bad 1.66 33Ex. 24 chloro- acid bis(2- PP mold surface xylylene mercapto accuracy, diiso- ethyl ester) Trans- cyanate 0.10 mol parent 0.10 mol__________________________________________________________________________

EXAMPLE 33

94 parts of m-xylylene diisocyanate, 122 parts of pentaerythritol tetrakis(3-mercaptopropionate), 0.05 part of dibutyl tin dilaurate, and 100 ppm of UNIDAIN DS-401 as an internal release agent (a nonionic surface action agent, manufactured by Daikin Kogyo Co.,Ltd.) were mixed, and the resulting mixture was then deaerated for 1 hour. Afterward, the mixture was cast into a mold prepared by combining a gasket with a lens matrix comprising two glass plates, and then was cured at 50.degree. C. for 6 hours, at 80.degree. C. for 2 hours, at 90.degree. C. for 2 hours, and at 110.degree. C. for 2 hours.

After polymerization, the lens was easily released, and the thus obtained lens was colorless and transparent, free from bubbles and strain, and good in surface accuracy. In a similar manner, a test piece was prepared for determining the transmittance and the total ray transmittance was measured and found to be 85%.

EXAMPLES 34-54

In the same manner as Example 33, lenses having compositions as shown in Table 3 were prepared, and the results are shown in Table 3.

EXAMPLE 55

94 parts of m-xylylene diisocyanate, 122 parts of pentaerythritol tetrakis(3-mercaptopropionate), 0.05 part of dibutyl tin dilaurate and 100 ppm of UNIDAIN DS-401 as an internal release agent (product of Daikin Kogyo Co.,Ltd.) were mixed, and the resulting uniform solution was cast into a mold prepared by combining a gasket with a lens matrix comprising two glass plates, and then was cured at 50.degree. C. for 6 hours, at 80.degree. C. for 2 hours, at 90.degree. C. for 2 hours, and at 110.degree. C. for 2 hours.

After the polymerization, the lens was released from the mold with ease. The thus obtained lens was colorless and transparent, free from bubbles and strain, and excellent in surface accuracy. The total ray transmittance was 85%.

EXAMPLE 56

94 parts of m-xylylene diisocyanate, 122 parts of pentaerythritol tetrakis(3-mercaptopropionate), 0.05 part of dibutyl tin dilaurate and 1000 ppm of dioctyl acid phosphate were mixed, and the resulting uniform solution was cast into a mold prepared by combining a gasket with a lens matrix comprising two glass plates, and then was cured at 50.degree. C. for 6 hours, at 80.degree. C. for 2 hours, at 90.degree. C. for 2 hours, and at 110.degree. C. for 2 hours.

After the polymerization, the lens was released from the mold with ease. The thus obtained lens was colorless and transparent, free from bubbles and strain, and excellent in surface accuracy. The total ray transmittance was 85%.

EXAMPLE 57

94 parts of m-xylylene diisocyanate, 122 parts of pentaerythritol tetrakis(3-mercaptopropionate) and 1000 ppm of dioctyl acid phosphate were mixed, and the resulting uniform solution was cast into a mold prepared by combining a gasket with a lens matrix comprising two glass plates, and then was heated and cured at 50.degree. C. for 6 hours, at 80.degree. C. for 6 hours, at 90.degree. C. for 6 hours, and at 120.degree. C. for 10 hours.

After the polymerization, the lens was released from the mold with ease. The thus obtained lens was colorless and transparent, free from bubbles and strain, and excellent in surface accuracy. The total ray transmittance was 85%.

COMPARATIVE EXAMPLE 25

A lens was prepared by the same procedure as in Example 33 except that DS-401 was not used. After the polymerization, the lens could not be released from the mold.

COMPARATIVE EXAMPLE 26

A lens was prepared by the same procedure as in Example 33 except that an internal release agent was not used and that a mold which had been treated with DIEFREE-MS-181 (a fluorine external release agent, product of Daikin Kogyo Co., Ltd.) as an external release agent was used. After the polymerization, the lens was easily released, but a part of the release agent had migrated to the surface of the lens, so that the lens was partly opaque. The surface accuracy was also poor.

COMPARATIVE EXAMPLE 27

A lens was prepared by the same procedure as in Example 33 except that an internal release agent was not used and that the glass mold was replaced with a polypropylene mold. After the polymerization, the lens was easily released, and the thus obtained lens was colorless and transparent, and free from bubbles and strain, but the surface accuracy was poor.

COMPARATIVE EXAMPLE 28

A lens was prepared by the same procedure as in Example 34 except that the internal release agent QS-120A was not used. After the polymerization, the lens could not be released from the mold.

COMPARATIVE EXAMPLE 29

A lens was prepared by the same procedure as in Comparative Example 26 except that the combination of the monomers in Example 34 was employed. The results are set forth in Table 3.

COMPARATIVE EXAMPLE 30

A lens was prepared by the same procedure as in Comparative Example 35 except that the combination of the monomers in Example 34 was employed. The results are set forth in Table 3.

COMPARATIVE EXAMPLE 31

94 parts of m-xylylene diisocyanate, 122 parts of pentaerythritol tetrakis(3-mercaptopropionate), 0.05 part of dibutyl tin dilaurate and 5,000 ppm of zinc stearate, the internal release agent described in EP 119471, were mixed, and the resulting mixture was then deaerated for 1 hour. Afterward, the mixture was cast into a mold comprising a glass mold and a gasket, and then was heated and cured at 50.degree. C. for 6 hours, at 80.degree. C. for 2 hours, at 90.degree. C. for 2 hours, and at 110.degree. C. for 2 hours.

After the polymerization, the resulting lens in the mold was whitely turbid and could not be released from the mold. As a consequence, the measurement of surface accuracy and optical strain was impossible.

COMPARATIVE EXAMPLES 32 TO 35

Each lens having each composition shown in Table 4 was prepared by the same procedure as in Comparative Example 31 except that zinc stearate was replaced with zinc stearate and lauric acid, zinc stearate and lauryl acid phosphate, zinc stearate and dioctyl acid phosphate, or calcium stearate which are described in EP 119471. The results are set forth in Table 4.

COMPARATIVE EXAMPLE 36

A lens having a composition shown in Table 4 was prepared by the same procedure as in Comparative Example 31 except that zinc stearate was replaced with dimethylglyoxime described in U.S. Pat. No. 4,220,727. The results are set forth in Table 4.

COMPARATIVE EXAMPLE 37

A lens having a composition shown in Table 4 was prepared by the same procedure as in Comparative Example 31 except that zinc stearate was replaced with hardened castor oil mentioned in C.A, 85(8), 47604v. The results are set forth in Table 4.

COMPARATIVE EXAMPLES 38 AND 39

A series of lenses having the compositions shown in Table 4 was prepared by the same procedure as in Comparative Example 31 except that zinc stearate was replaced with oleyl amide oleate or N,N-dimethyloleic amide mentioned in BE 757939 Patent. The results are set forth in Table 4.

COMPARATIVE EXAMPLES 40, 41 AND 42

A series of lenses having the compositions shown in Table 4 was prepared by the same procedure as in Comparative Example 31 except that zinc stearate was replaced with each of silicone oils or wax as known internal release agents mentioned in column 1, lines 35 to 38 of U.S. Pat. No. 4,728,690, i.e., TSF 4300 and TSF 4440 which are silicone oils made by Toshiba Silicone Co., Ltd or a liquid paraffin. The results are set forth in Table 4.

COMPARATIVE EXAMPLE 43

A lens having a composition shown in Table 4 was prepared by the same procedure as in Comparative Example 31 except that zinc stearate was replaced with an oleyl amine ethylene oxide adduct mentioned in Japanese Patent Laid-open Publication No. 51707/1985. The results are set forth in Table 4.

COMPARATIVE EXAMPLE 44

A lens having a composition shown in Table 4 was prepared by the same procedure as in Comparative Example 31 except that zinc stearate was replaced with hexadecanol ethyleneoxide adduct mentioned in Japanese Patent Laid-open Publication No. 81220/1985. The results are set forth in Table 4.

COMPARATIVE EXAMPLE 45

A lens having a composition shown in Table 4 was prepared by the same procedure as in Comparative Example 31 except that zinc stearate was replaced with carboxyl alkylsiloxane mentioned in U.S. Pat. No. 4,220,727. The results are set forth in Table 4.

TABLE 3__________________________________________________________________________ Isocyanate Thiol Catalyst Release agent Heating conditions of (parts) (parts) (parts) (ppm) polymerization__________________________________________________________________________Example 33 m-XDI PEMP DBTDL DS-401 50.degree. C. (6 hr), 80.degree. C. (2 hr) (94) (122) (0.05) (100) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Example 34 p-XDI m-xylylene- DBTDL QS-120 A 50.degree. C. (6 hr), 80.degree. C. (2 hr) (100) dithiol (90) (0.1) (150) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Example 35 m-XDI 1,3,5-tris(3- DBTDL DS-403 50.degree. C. (6 hr), 80.degree. C. (2 hr) (188) mercaptopropyl) (0.1) (50) and 90.degree. C. (2 hr), 110.degree. C. (2 hr) isocyanurate QS-120 A (140), and m- (100) xylylenedithiol (68)Example 36 m-XDI PEMP DBTDL EF-122 A 50.degree. C. (6 hr), 80.degree. C. (2 hr) (94) (122) (0.05) (500) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Example 37 p-XDI m-xylylene- DBTDL EF-126 50.degree. C. (6 hr), 80.degree. C. (2 hr) (100) dithiol (90) (0.1) (250) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Example 38 m-XDI PEMP DBTDL EF-301 50.degree. C. (6 hr), 80.degree. C. (2 hr) (94) (122) (0.05) (200) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Example 39 m-XDI PEMP DBTDL trimethylcetyl 50.degree. C. (6 hr), 80.degree. C. (2 hr) (94) (122) (0.05) ammonium 90.degree. C. (2 hr), 110.degree. C. (2 hr) chloride (500)Example 40 p-XDI m-xylylene- DBTDL trimethylcetyl 50.degree. C. (6 hr), 80.degree. C. (2 hr) (100) dithiol (90) (0.1) aryl ammonium 90.degree. C. (2 hr), 110.degree. C. (2 hr) chloride (1000)Example 41 m-XDI 1,3,5-tris(3- DBTDL dimethylethylcetyl 50.degree. C. (6 hr), 80.degree. C. (2 hr) (188) mercaptopropyl) (0.1) ammonium 90.degree. C. (2 hr), 110.degree. C. (2 hr) isocyanurate chloride (140), and m- (2000) xylylenedithiol (68)Example 42 m-XDI PEMP DBTDL triethyldodecyl 50.degree. C. (6 hr), 80.degree. C. (2 hr) (94) (122) (0.05) ammonium 90.degree. C. (2 hr), 110.degree. C. (2 hr) chloride (1000)Example 43 m-XDI PEMP DBTDL trioctylmethyl 50.degree. C. (6 hr), 80.degree. C. (2 hr) (94) (122) (0.05) ammonium 90.degree. C. (2 hr), 110.degree. C. (2 hr) chloride (1000)Example 44 m-XDI PEMP DBTDL diethylcyclo- 50.degree. C. (6 hr), 80.degree. C. (2 hr) (94) (122) (0.05) hexyldodecyl 90.degree. C. (2 hr), 110.degree. C. (2 hr) ammonium sulfate (1000)Example 45 m-XDI PEMP DBTDL diisopropyl (94) (122) (0.05) acid phosphate (500)Example 46 p-XDI m-xylylene- DBTDL dibutyl acid 50.degree. C. (6 hr), 80.degree. C. (2 hr) (100) dithiol (90) (0.1) phosphate (1000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Example 47 m-XDI 1,3,5-tris(3- DBTDL octyl acid 50.degree. C. (6 hr), 80.degree. C. (2 hr) (188) mercaptopropyl) (0.1) phosphate (1000) 90.degree. C. (2 hr), 110.degree. C. (2 hr) isocyanurate (140), and m- xylylenedithiol (68)Example 48 m-XDI PEMP DBTDL dioctyl acid 50.degree. C. (6 hr), 80.degree. C. (2 hr) (941 (122) (0.05) phosphate (1000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Example 49 m-XDI PEMP DBTDL isodecyl acid 50.degree. C. (6 hr), 80.degree. C. (2 hr) (94) (122) (0.05) phosphate (1000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Example 50 m-XDI PEMP DBTDL bis(tridecyl) acid 50.degree. C. (6 hr), 80.degree. C. (2 hr) (94) (122) (0.05) phosphate 90.degree. C. (2 hr), 110.degree. C. (2 hr) (1000)Example 51 1,3-bis(.alpha.,.alpha.- PEMP DBTDL DS-401 50.degree. C. (6 hr), 80.degree. C. (2 hr) dimethyl (122) (0.05) (100) 90.degree. C. (2 hr), 110.degree. C. (2 hr) isocyanato methyl)benzene (172)Example 52 p-XDI dipentaerythri- DBTDL QS-120A 50.degree. C. (6 hr), 80.degree. C. (2 hr) (100) tol hexakis(3- (0.1) (150) 90.degree. C. (2 hr), 110.degree. C. (2 hr) mercaptopropio- nate) (46)Example 53 hexamethylene 1,3,5-tris(3- DBTDL DS-403 (50), and 50.degree. C. (6 hr), 80.degree. C. (2 hr) diisocyanate mercaptopropyl) (0.1) QS-120A (100) 90.degree. C. (2 hr), 110.degree. C. (2 hr) (168) isocyanurate (140) and m- xylylenedithiol (68)Example 54 isophorone 1,3,5-tris(3- DBTDL dimethylethyl- 50.degree. C. (6 hr), 80.degree. C. (2 hr) diisocyanate mercaptopropyl) (0.1) cetyl ammonium 90.degree. C. (2 hr), 110.degree. C. (2 hr) (223) isocyanurate chloride (140), and m- (2000) xylylenedithiol (68)Example 55 m-XDI PEMP DBTDL DS-401 50.degree. C. (6 hr), 80.degree. C. (2 hr) (94) (122) (0.05) (100) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Example 56 m-XDI PEMP DBTDL dioctyl acid 50.degree. C. (6 hr), 80.degree. C. (2 hr) (94) (122) (0.05) phosphate (1000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Example 57 m-XDI PEMP -- dioctyl acid 50.degree. C. (6 hr), 80.degree. C. (6 hr) (94) (122) phosphate (1000) 90.degree. C. (6 hr), 120.degree. C. (10 hr)Comparative m-XDI PEMP DBTDL 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 25 (94) (122) (0.05) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative m-XDI PEMP DBTDL DIEFREE MS-181 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 26 (94) (122) (0.05) (external) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative m-XDI PEMP DBTDL PP mold was 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 27 (94) (122) (0.05) used 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative p-DXI m-xylylene- DBTDL 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 28 (100) dithiol (90) (0.1) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative p-XDI m-xylylene- DBTDL DIEFREE MS-181 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 29 (100) dithiol (90) (0.1) (external) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative p-XDI m-xylylene- DBTDL PP mold was 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 30 (100) dithiol (90) (0.1) used. 90.degree. C. (2 hr), 110.degree. C. (2 hr)__________________________________________________________________________ m-XDI: mxylylene diisocyanate pXDI: pxylylene diisocyanate PEMP: pentaerythritol tetrakis (3mercaptopropionate) DBTDL: dibutyl tin dilaurate Surface Strain Releasability Transparency accuracy__________________________________________________________________________Example 33 .largecircle. .largecircle. .largecircle. .largecircle.Example 34 .largecircle. .largecircle. .largecircle. .largecircle.Example 35 .largecircle. .largecircle. .largecircle. .largecircle.Example 36 .largecircle. .largecircle. .largecircle. .largecircle.Example 37 .largecircle. .largecircle. .largecircle. .largecircle.Example 38 .largecircle. .largecircle. .largecircle. .largecircle.Example 39 .largecircle. .largecircle. .largecircle. .largecircle.Example 40 .largecircle. .largecircle. .largecircle. .largecircle.Example 41 .largecircle. .largecircle. .largecircle. .largecircle.Example 42 .largecircle. .largecircle. .largecircle. .largecircle.Example 43 .largecircle. .largecircle. .largecircle. .largecircle.Example 44 .largecircle. .largecircle. .largecircle. .largecircle.Example 45 .largecircle. .largecircle. .largecircle. .largecircle.Example 46 .largecircle. .largecircle. .largecircle. .largecircle.Example 47 .largecircle. .largecircle. .largecircle. .largecircle.Example 48 .largecircle. .largecircle. .largecircle. .largecircle.Example 49 .largecircle. .largecircle. .largecircle. .largecircle.Example 50 .largecircle. .largecircle. .largecircle. .largecircle.Example 51 .largecircle. .largecircle. .largecircle. .largecircle.Example 52 .largecircle. .largecircle. .largecircle. .largecircle.Example 53 .largecircle. .largecircle. .largecircle. .largecircle.Example 54 .largecircle. .largecircle. .largecircle. .largecircle.Example 55 .largecircle. .largecircle. .largecircle. .largecircle.Example 56 .largecircle. .largecircle. .largecircle. .largecircle.Example 57 .largecircle. .largecircle. .largecircle. .largecircle.Comparative -- X -- --Example 25Comparative .largecircle. .largecircle. X XExample 26Comparative .largecircle. .largecircle. X XExample 27Comparative -- X -- --Example 28Comparative .largecircle. .largecircle. X XExample 29Comparative .largecircle. .largecircle. .largecircle. XExample 30__________________________________________________________________________ TABLE 4__________________________________________________________________________ Isocyanate Thiol Catalyst Release agent Heating conditions of (parts) (parts) (parts) (ppm) polymerization__________________________________________________________________________Comparative m-XDI PEMP DBTDL Zinc Stearate 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 31 (94) (122) (0.05) (5000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative m-XDI PEMP DBTDL Zinc Stearate 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 32 (94) (122) (0.05) (5000) and 90.degree. C. (2 hr), 110.degree. C. (2 hr) Lauric acid 50.degree. C. (6 hr), 80.degree. C. (2 hr) (15000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative m-XDI PEMP DBTDL Zinc Stearate 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 33 (94) (122) (0.05) (5000) and 90.degree. C. (2 hr), 110.degree. C. (2 hr) Lauryl acid phosphate 50.degree. C. (6 hr), 80.degree. C. (2 hr) (1000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative m-XDI PEMP DBTDL Zinc Stearate 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 34 (94) (122) (0.05) (5000) and 90.degree. C. (2 hr), 110.degree. C. (2 hr) Dioctyl acid phospate 50.degree. C. (6 hr), 80.degree. C. (2 hr) (1000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative m-XDI PEMP DBTDL Calcium stearate 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 35 (94) (122) (0.05) (5000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative m-XDI PEMP DBTDL Dimethyl glyoxime 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 36 (94) (122) (0.05) (5000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative m-XDI PEMP DBTDL Hardened castor 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 37 (94) (122) (0.05) oil (10000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative m-XDI PEMP DBTDL Oleyl amide oleate 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 38 (94) (122) (0.05) (5000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative m-XDI PEMP DBTDL N,N-dimethyl 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 39 (94) (122) (0.05) oleic amide (5000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative m-XDI PEMP DBTDL TSF 4300 (Silicone 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 40 (94) (122) (0.05) oil) (500) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative m-XDI PEMP DBTDL TSF 4440 (Silicone 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 41 (94) (122) (0.05) oil) (500) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative m-XDI PEMP DBTDL Liquid paraffin 50.degree. C. (6 hr), 80.degree. C. (2 hr)Example 42 (94) (122) (0.05) (1000) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative Example 43 m-XDI (94) PEMP (122) DBTDL (0.05) ##STR1## 50.degree. C. (6 hr), 80.degree. C. (2 hr) 90.degree. C. (2 hr), 110.degree. C. (2 hr)Comparative Example 44 m-XDI (94) PEMP (122) DBTDL (0.05) ##STR2## 50.degree. C. (6 hr), 80.degree. C. (2 hr) 90.degree. C., 110.degree. C. (2 hr)Comparative Example 45 m-XDI (94) PEMP (122) DBTDL (0.05) ##STR3## 50.degree. C. (6 hr), 80.degree. C. (2 hr) 90.degree. C., 110.degree. C. (2__________________________________________________________________________ hr) Note: mXDI, pXDI, PEMP and DBTDL are as defined in Table 3. Optical Surface Strain Releasability Transparency accuracy Remarks__________________________________________________________________________Comparative -- X X -- EP 119471Example 31Comparative -- X X -- EP 119471Example 32Comparative X .largecircle. X .largecircle. EP 119471Example 33Comparative X .largecircle. X .largecircle. EP 119471Example 34Comparative -- X X -- EP 119471Example 35Comparative -- X X -- USP 4220727Example 36Comparative -- X X -- C.A. 85(8) 47604 vExample 37Comparative -- X X -- BE 757939Example 38Comparative -- X X -- BE 757939Example 39Comparative -- X X -- USP 4728690Example 40 Col. 1 lines 35-38Comparative -- X X -- USP 4728690Example 41 Col. 1 lines 35-38Comparative -- X X -- USP 4728690Example 42 Col. 1 lines 35-38Comparative -- X X -- Japanese Patent Laid-open No. 51707/1985,Example 43 Example 1, Internal release agentComparative -- X X -- Japanese Patent Laid-open No. 81220/1985,Example 44 Example 2, Internal release agentComparative -- X X -- USP 4220727Example 45__________________________________________________________________________

As discussed above, when a release agent is not used, the lens is not released from the mold. Furthermore, when a known external release agent which is utilized to mold a urethane resin is used, releasing is achieved, but a lens having high transparency and optical homogeneity cannot be obtained. When a polyolefin resin mold is used, a lens having good surface accuracy cannot be obtained.

Moreover, when a known internal release agent which is utilized to mold a urethane resin is used with the sulfur-containing urethane of the second aspect of the invention. (Comparative Examples 31 to 45), the resulting lens is whitely turbid and cannot be released.

On the contrary, when the surface active agent of the second aspect of the present invention is used as the internal release agent, a lens having high transparency and optical homogeneity can be obtained.

Claims

1. A process for producing a plastic lens comprising adding at least one surface active agent selected from the group consisting of fluorine-containing nonionic surface active agents, silicone-containing nonionic surface active agents and alkyl quaternary ammonium salts as an internal mold releasing agent to a mixture of one or more polyisocyanate compounds and one or more active hydrogen compounds selected from the group consisting of polyol compounds and polythiol compounds having at least one sulfur atom in addition to the mercapto groups and conducting cast polymerization in a lens mold made of glass or metal so as to form a plastic lens.

2. A plastic lens produced by the process of claim 1.

3. The process of claim 1 wherein the polyol compounds are sulfur-containing polyol compounds.

4. A plastic lens produced by the process of claim 3.

5. The process of claim 1 wherein the proportion of the polyisocyanate compound to the active hydrogen compound is a molar ratio of from about 0.5 to about 3.0 moles of functional isocyanate group per mole of functional (SH+OH) group.

6. A plastic lens produced by the process of claim 5.

7. The process of claim 1 wherein the internal mold releasing agent is a fluorine-containing nonionic surface active agent.

8. The process of claim 1 wherein the internal mold releasing agent is a silicone-containing nonionic surface active agent.

9. The process of claim 1 wherein the internal mold releasing agent is an alkyl quaternary ammonium salt.

10. A plastic lens produced by the process of claim 7.

11. A plastic lens produced by the process of claim 8.

12. A plastic lens produced by the process of claim 9.

13. The process of claim 1 wherein the internal mold releasing agent is present in an amount of from about 0.1 to about 10,000 ppm per sum of the polyisocyanate compound and the active hydrogen compound.

14. A plastic lens produced by the process of claim 13.

15. The process of claim 1 wherein cast polymerization is carried out at a temperature of from about -50.degree. C. to about 200.degree. C.

16. A process for preparing a sulfur-containing urethane resin lens which comprises pouring a mixture of polyisocyanate having two or more isocyanato groups, polythiol having two or more thiol groups, and one or more surface active agent selected from the group consisting of fluorine-containing nonionic surface active agents, silicone-containing nonionic surface active agents and alkyl quaternary ammonium salts into a mold made of glass or metal, heating and cast polymerizing the same.

17. The process for preparing a sulfur-containing urethane resin lens of claim 16 wherein said fluorine-containing nonionic surface active agents are nonionic surface active agents having a perfluoroalkyl group and a hydroxyalkyl group or a phosphate ester group.

18. The process for preparing a sulfur-containing urethane resin lens of claim 16 wherein said silicone-containing nonionic surface active agents are nonionic surface active agents having a dimethylsiloxane group and a hydroxylalkyl group or a phosphate ester group.

19. The process for preparing a sulfur-containing urethane resin lens of claim 16 wherein said alkyl quaternary ammonium salt is one or more selected from halogen salts, phosphates and sulphates of trimethylcetyl ammonium, trimethylstearyl ammonium, dimethylethylcetyl ammonium, triethyldodecyl ammonium, trioctyldodecyl ammonium and diethylcyclohexyldodecyl ammonium.

20. The process for preparing a sulfur-containing urethane resin lens of claim 16 wherein said polyisocyanate is one or more polyisocyanates selected from the group consisting of aliphatic polyisocyanates, aliphatic polyisocyanates having an aromatic ring and alicyclic polyisocyanates.

21. The process for preparing a sulfur-containing urethane resin lens of claim 20 wherein said aliphatic polyisocyanate, aliphatic polyisocyanate having an aromatic ring or alicyclic polyisocyanate is one or more polyisocyanates selected from the group consisting of xylylene diisocyanate, bis(.alpha.,.alpha.-dimethyl isocyanato methyl)benzene, isophorone diisocyanate and hexamethylene diisocyanate.

22. The process for preparing a sulfur-containing urethane resin lens of claim 16 wherein said polythiol is at least one polythiol selected from the group consisting of aliphatic polythiols, alicyclic polythiols, polythiols having an aromatic ring, polythiols having a heterocyclic ring and halogen-substituted compounds of these polythiols.

23. The process for preparing a sulfur-containing urethane resin lens of claim 22 wherein said polythiol is a polythiol having at least three thiol groups.

24. The process for preparing a sulfur-containing urethane resin lens of claim 22 wherein said polythiol is one or more polythiols selected from the group consisting of pentaerythritol tetrakis(3-mercapto-propionate), dipentaerythritol hexakis(3-mercapto-propionate), xylylenedithiol and 1,3,5 tris(3-mercapto-propyl) isocyanurate.

25. The process for preparing a sulfur-containing urethane resin lens of claim 16 wherein said surface active agent is present in an amount of from about 1 ppm to about 10,000 ppm with respect to the total weight of the polyisocyanate and the polythiol.

26. The process for preparing a sulfur-containing urethane resin lens of claim 16 wherein said surface active agent is present in an amount of from about 1 ppm to about 5,000 ppm with respect to the total weight of the polyisocyanate and the polythiol.

27. The process for preparing a sulfur-containing urethane resin lens of claim 16 wherein the ratio of said polyisocyanate to said polythiol is from about 0.5:1.0 to about 3.0:1.0 in terms of an NCO/SH equivalent ratio.

28. The process for preparing a sulfur-containing urethane resin lens of claim 16 wherein the ratio of said polyisocyanate to said polythiol is from about 0.5:1.0 to about 1.5:1.0 in terms of an NCO/SH equivalent ratio.

29. A lens prepared by the process of claim 16.