CN1032795C - 制造亲水性接触透镜的改进方法 - Google Patents

制造亲水性接触透镜的改进方法 Download PDF

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CN1032795C
CN1032795C CN90107179A CN90107179A CN1032795C CN 1032795 C CN1032795 C CN 1032795C CN 90107179 A CN90107179 A CN 90107179A CN 90107179 A CN90107179 A CN 90107179A CN 1032795 C CN1032795 C CN 1032795C
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lens
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CN1049628A (zh
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丹尼斯·哈恩
加里·A·约翰松
多米尼克·V·鲁肖
克里斯托弗·E·布兰克
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Bausch and Lomb Inc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
    • B29C33/60—Releasing, lubricating or separating agents
    • B29C33/62—Releasing, lubricating or separating agents based on polymers or oligomers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00038—Production of contact lenses
    • B29D11/00125—Auxiliary operations, e.g. removing oxygen from the mould, conveying moulds from a storage to the production line in an inert atmosphere
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
    • G02B1/041—Lenses
    • G02B1/043—Contact lenses
    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00—Optical parts
    • G02C7/02—Lenses; Lens systems ; Methods of designing lenses
    • G02C7/04—Contact lenses for the eyes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0002—Condition, form or state of moulded material or of the material to be shaped monomers or prepolymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0092—Other properties hydrophilic

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Ophthalmology & Optometry (AREA)
  • Manufacturing & Machinery (AREA)
  • Optics & Photonics (AREA)
  • General Physics & Mathematics (AREA)
  • General Health & Medical Sciences (AREA)
  • Eyeglasses (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
  • Treatments Of Macromolecular Shaped Articles (AREA)
  • Encapsulation Of And Coatings For Semiconductor Or Solid State Devices (AREA)

Abstract

本发明涉及一种制造接触透镜的改进方法，该方法是将单体或共聚单体混合物引入模腔中并使其处于聚合的条件下聚合得到所需形状的聚合物制件。其特征在于：在单体混合物中加入一种脱模剂，该脱模剂选自一种亲水性聚合物与亲油性化合物的混合物，并且，脱模剂在单体混合物中所占比例小于3%(重量)。

Description

制造亲水性接触透镜的改进方法
通常，接触透镜是用车削，模塑和旋转铸造三种通用方法之一制造的。上述方法各有其优缺点。例如：车削方法要将一圆盘形透镜坯料的两个表面各切掉一部分，以形成透镜的前部和后部，这种方法是三种方法中加工费用最高的，但它可使设计具有较大的自由度，而模塑或旋转铸造方法是做不到这一点的。
但是，采用模塑和旋转铸造方法制造透镜几乎不需后加工，在这两种方法中透镜的前后表面一步成形，模塑方法是用模具的表面来限定透镜的前后表面的；旋转铸造的方法是用模具限定透镜的前表面，而后表面则是靠旋转单体溶液产生的力来成形的。由于这两种方法减少了加工步骤，因而制品的生产成本便大大降低。
然而，在旋转铸造和模塑过程中，透镜往往粘在模具表面，这显然是由于聚合过程中单体混合物与模具表面的化学作用造成的，这种现象在旋转铸造和模塑加工中是不可避免的。一般是将透镜材料水化来克服上述缺点的，水化能够减弱透镜与模具间的相互作用，从而可将透镜轻轻从模腔中脱出。这样，透镜脱膜时是极软的。
铸造的接触透镜要经过严格检验，避免外观缺陷和边缘缺陷，以确保光学性能。但对于水化的软透镜，这种检验非常困难，并且费工费时；而干凝胶透镜(未水化透镜、硬透镜)很容易进行检验，因此，以硬透镜形式脱模，对其进行检验，然后再将其水化成水凝胶，可使生产成本降低。
为了使软接触透镜能以干燥形式脱模，人们进行过许多尝试。例如：美国专种第2542286号公开了向树脂制作的光学器件中加入“润滑剂”的方法。
美国专利第3171869号公开了一种使塑料透镜脱模的方法，该方法包括将树脂在25-125℃下聚合到凝胶态，再于125-235℃加热该凝胶，使其成为硬化的树脂。
美国专利第3,944,637号提出：使用特定的共聚单体混合物，以达到脱模的效果。这三个专利介绍的方法都是将透镜从玻璃模腔中脱出。而目前在制造接触透镜过程中大多采用塑料模具，美国专利第4155962号对比有介绍，其中公开了一种通过向模具的不同侧面施加作用力而将干凝胶透镜从模具中脱出的方法。
美国专利第4159292号公开了在塑料模具材料中加入内润滑剂来控制接触透镜从塑料模具中脱模的方法。
美国专利第4534916号指出，向共聚单体中加入表面活性剂可制备具有改进表面质量的透镜。采用这种表面活性剂可以减少透镜表面缺陷的数目。其中实施例表明：采用旋转铸造方法，透镜能从模具中脱出。
本发明涉及一种制造接触透镜的改进方法，其特征在于：不需将透镜水化为水凝胶态便可直接脱模。这项改进是将共聚单体混合物与0.001～3％(重量)的脱模剂混合后进行铸造，该脱模剂为亲水的非反应性聚合物与亲油性化合物(例如：饱和或不饱和脂肪酸或醇)的混合物。当透镜在模具中聚合至干凝胶态之后，便可将塑料模具变形从而使处于非水化状态的透镜脱模。
本发明者发现：在制造透镜用的单体或共聚单体混合物中加入亲水性聚合物与亲油性化合物的混合物，可制得能够以干燥状态从塑料模具中脱模的硬质干凝胶透镜。按这种方法制作出来的透镜在物理性能上与现有技术制作的完全相同。而由于透镜仍处于硬质状态，因此可以简化以往将其加工为合格透镜产品所需的铸造后续工序，这是本发明的优越性所在。
在聚合单体中加入0.001～5.0％(重量)的亲水性聚合物与亲油性化合物的混合物可有效地使透镜干态脱模，优选范围是0.1～1.0％(重量)，业已发现亲水性聚合物与亲油性化合物的比例应取5/1～1/5(重量比)，最优选4/1～1/1(重量比)。
本发明已经证实的效果较好的亲水性聚合物包括聚乙二醇和聚丙二醇，该亲水性聚合物的平均分子量在200～10000之间，优选2000～4000。
其它的亲水性聚合物亦可在本发明方法中使用，只要它不参与制作透镜的聚合过程，并且要求其溶解度参数与共聚单体及最终聚合物的溶解度参数接近，以免使最终产品形成多相。分相会使接触透镜成为不透明体。
本发明所用的亲油性化合物从脂肪酸和脂肪醇中选取较佳。具体的例子包括：硬脂酸，油酸，亚油酸，棕榈油酸，肉豆蔻酸，月桂酸棕榈酸，花生酸，二十四烷酸及其羟基类似物。亦可用其它的亲油性化合物，只要它在制备透镜的聚合过程中是相对非活性的，并且用量是够小，足以避免在聚合过程中与共聚单体混合物形成多相。分相会导致产生不透明的透镜。
本发明中的接触透镜材料可采用任何“水凝胶材料”，包括基于聚甲基丙烯酸羟乙酯和聚乙烯基吡咯烷酮的体系，以及许多以甲基丙烯酸羟乙酯和/或乙烯基吡咯烷酮为单体的共聚物体系。
用亲水性聚合物与亲油性化合物相结合来改进接触透镜的生产工艺，可以用于旋转铸造技术和模塑技术。在所述模塑技术中使用两件模具，正如下列专利中所公开的技术：美国专利第3881683号，第4197226号，第4121896号和英国专利申请第2185933号。亦可用于其它已知可用来制作接触透镜的铸造和模塑技术。
下面是本发明的一些实施例，但并未包括本发明的全部范围。
实施例1-按先有技术对PHEMA透镜干燥脱模
将含甲基丙烯酸-2-羟乙酯85％(重量)，甘油15％(重量)，二甲基丙烯酸乙二醇酯0.35％(重量)和自由基聚合催化剂苯偶姻乙醚(BME)0.18％(重量)的混合物用塑料模具施转铸造接触透镜，当透镜在模具中固化后，通过使模具变形将透镜干态脱模。
取出的透镜中无破损或其它表面损伤的小于1％，因而这种方法在工业上和临床上都是不可接受的。
实施例2-加入亲水性聚合物之后对透镜干燥脱模的尝试
向实施例1所述的预聚混合物中加入不同量的亲水性聚合物。例如：向该混合物中加入0.5％(重量)的聚丙二醇(分子量约4000)，用铸造方法制透镜，透镜干燥脱模的情况有所改善，但是，仍然有透镜与模腔表面粘连的趋势。
实施例3-按本发明的新方法，透镜干燥脱模
除了共聚单体混合物中加有0.25重量份数的下述混合物之外，所用的共聚单体混合物与实施例1和2的完全相同。
A.0.06重量份硬脂酸/0.19重量份聚乙二醇(分子量3,000)
B.0.06重量份丁二酸/0.19重量份聚乙二醇(分子量3,000)
C.0.06重量份硬酯酸/0.19重量份聚乙二醇(分子量4,000)
D.0.06重量份硬酯酸/0.19重量份聚乙二醇(分子量3,300)
将透镜在PVC模具中铸造，并进行干态脱模。用测定结构的工业方法对透镜进行检验并评估(仅对未破损透镜进行)。
混合物    铸造透镜数    受验透镜数    合格透镜数
  A          25            19            10
  B          25            15            9
  C          25            24            19
  D          23            23            23
这表明本例所制备的透镜明显优于实施例1和2中铸造的透镜(在实施例1和2中有效生产率均为零)。仅加入聚乙二醇亦可得到高于现有技术的产率，但是，该聚合物必须有效高的浓度。
从而可知，加入亲水性聚合物和亲油性化合物可显著提高干燥脱模透镜的生产效率。

Claims (4)

1.一种制造接触透镜的改进方法，其中将单体或共聚单体混合物置于由聚氯乙烯制成的模腔中并在聚合条件下聚合得到聚合的型材，该方法的特征在于：在单体混合物中加入一种脱模剂，其中所述脱模剂占所述单体混合物的0.001-3％(重量)，并且它是非反应性的聚乙二醇或聚丙二醇和脂肪酸的混合物。
2.权利要求1所述的方法，其中该方法使用的单体混合物选自水凝胶材料，包括乙烯基吡咯烷酮和甲基丙烯酸-2-羟乙酯。
3.权利要求1所述的方法，其中所述非反应性聚乙二醇的平均分子量为2000-4000，而所述聚丙二醇的平均分子量为2000-4000。
4.权利要求1所述的方法，其中使用的脂肪酸选自油酸，亚油酸，棕榈油酸，月桂酸，肉豆蔻酸，棕榈酸，硬脂酸，    花生酸和二十四烷酸。
CN90107179A 1989-08-21 1990-08-20 制造亲水性接触透镜的改进方法 Expired - Fee Related CN1032795C (zh)

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US397,143 1989-08-21
US07/397,143 US4983332A (en) 1989-08-21 1989-08-21 Method for manufacturing hydrophilic contact lenses
SG34394A SG34394G (en) 1989-08-21 1994-03-08 Improved method for manufacturing hydrophilic contact lenses

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CA2020196A1 (en) 1991-02-22
US4983332A (en) 1991-01-08
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DE69004045D1 (de) 1993-11-25
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CN1049628A (zh) 1991-03-06
SG34394G (en) 1994-07-08
AU624523B2 (en) 1992-06-11
KR910004336A (ko) 1991-03-28
EP0420403B1 (en) 1993-10-20
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JPH0389314A (ja) 1991-04-15
DE69004045T2 (de) 1994-02-17
ATE96085T1 (de) 1993-11-15
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KR950013674B1 (ko) 1995-11-13
AU5974890A (en) 1991-02-21

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