CN1073011C - 眼用透镜模具的处理方法及装置 - Google Patents

眼用透镜模具的处理方法及装置 Download PDF

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CN1073011C
CN1073011C CN93112966A CN93112966A CN1073011C CN 1073011 C CN1073011 C CN 1073011C CN 93112966 A CN93112966 A CN 93112966A CN 93112966 A CN93112966 A CN 93112966A CN 1073011 C CN1073011 C CN 1073011C
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J·P·阿当斯
E·C·拉斯特雷里
J·C·希顿
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Johnson and Johnson Vision Care Inc
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Abstract

一种在加注单体及透镜聚合前引导加速电子至一眼用模具的一个表面的至少一部分上的装置及方法。特别地已经发现，借助电晕处理电极所产生的电离氧可充分增强聚合物对如此处理的模具件的附着。在较佳实施例中，围绕此透镜模具的凸阳模具的凸缘得到电晕处理，以当模具在镜片聚合后被分开时，围绕透镜模腔周围的过量聚合材料的飞边附着于该阳的凸模具上，同时该透镜与阴性凹模具一同移出。

Description

眼用透镜模具的处理方法及装置
本发明涉及把模制眼用透镜从制造它的模具中取出的改进方法和装置，特别地，本发明适于诸如水凝胶隐形眼镜的模制眼用透镜，尽管此方法也适用于其他小型高精度眼用透镜-如眼内透镜(intraocular lenses)。
安置在眼角膜或眼内的软性眼用透镜，诸如隐形眼镜片或软性眼内透镜片，可由多种不同的技术所制成。隐形眼镜片可由在转动模具中回旋成型单体材料并随后聚合如此成形的该材料而制成。制造隐形眼镜片及眼内透镜片二者的另一方法，是用车床精确地切削一片材料，然后抛光该片材料，并将其用作透镜。
近来软性隐形眼镜片及软性眼内透镜片的模制已为人所喜爱。此项技术与先前的制造镜片方法相比，具有可重复性及速度快的优点。可成功地模制此种镜片的技术，能在颁给拉森的美国专利第4,495,313及4,640,489号与颁给拉森等人的美国专利第4,889,664、4,680,336及5,039,459中找到。这些专利特别说明一种稀释剂的使用，一种在模制过程中用以代替水的稀释材料，而在完成模造后此稀释材料又被水所取代。此一技术的优点，是如此制造出来的透镜的光学特性、大小及形状，不会如同不使用此种稀释剂的方法那样发生严重改变。
在本领域中已知的，还有通过在用诸如聚苯乙烯或聚丙烯所制成的模具中，成型单体或单体混合物，来制造这类眼用透镜。
此技术的一个例子，可在颁给拉森的美国专利第4,565,348号中找到。该专利中所讨论的是对聚苯乙烯模具的要求，即材料、化学及处理过程须加控制，以使模具不致因与透镜或彼此粘连而需要特别的力才能分开。
与上述聚苯乙烯模具不同，另一例子如颁给shepherd的美国专利第4,121,896号中所述，使用聚丙烯或聚乙烯模具。
然而，一个特殊问题为单体或单体混合物被过量地供给凹模具件。在合模及由此确定透镜片时，过多的单体或单体混合物被从模具腔排出，并停在一或两模具件的凸缘之上或之间，形成一环状环或环绕形成的透镜的飞边。
在分开两件模具后，已聚合过量的材料的周围飞边通常留置在阴模件即留滞透镜的模具件中。为便于进一步通过水合作用、检查、包装、消毒等处理透镜，需从该阴模具件除去聚合材料的飞边。当该飞边随同透镜与阴模具件留置在一起时，可用手指以人工方式撕去。
因而本发明的目的，是提供一种从留有眼用透镜的模具内移除眼用透镜及周围飞边而不需人的介入的装置。本发明通过降低成本、增加生产量及可作自动化，可使透镜制造程序的此一部分大为简化。
更具体地，本发明的目的，是提供一种在分开模具时使眼用透镜与飞边分开的方法及装置。
本发明的上述目的，是通过提供一种方法和装置而实现的；该方法和装置，最好通过在填注单体和透镜聚合之前把加速的电子引到一个模具的一个表面的至少一部分上，增加了表面能。模具在一件上包含有与另一件进行线接触的边缘，从而在两件合模时在其之间形成腔，以成形透镜。特别地，已发现借助电晕处理电极的电离氧的产生，大大增加了聚合物对如此处理过的模具的附着性。在最佳实施例中，围绕透镜模的凸模的飞边得到了电晕处理，从而在透镜聚合化后分离模件时，在把透镜从阴的凹模中聚出的同时，围绕透镜腔的多余聚合材料飞边附在阳的凸模具凸缘上。
图1a-1c显示了本发明改进的液体/固体表面相互作用特性及其测量装置。
图2是本发明的电极与阳模具的放大横截面图。
图3显示了包含图2的电极以处理多个阳模具的本发明装置的模截面图。
图4显示了一对合上的模具的剖视图。
聚合单体材料对模具(该单体材料即在此模具内予以成形并聚合)的附着力与模具材料的表面能有关。表面能是与液体表面张力类似的材料特性，它决定该材料的可湿性，并以每厘米达因来度量。
材料的表面能可由接触角的测量确定。使用一测角器测量固体表面上的液体小滴的接触角，即可确定此表面能。所量得的接触角愈小，该表面会愈湿。
参见图1a，其中显示了表示液体小滴14所构成的接触角12的常用测角器标度10。图1b显示了在具有不良的表面可湿性的衬底16上的液滴14；该液滴形成的接触角12远大于90°。参见图1c，其中再次显示了液滴14和衬底16，在此情况下表面可湿性良好。与图1b不同，这里接触角小于60°，表明材料所具有的表面能超过湿润液体表面张力至少每厘米10达因。
因基体表面上液体的可湿性严格而言并非基体表面能的函数，而是基体与湿润液体间的差异的结果，故表面能虽是可湿性的一项指示，但不能单独用作所有液体的接触角的最终表示。
在本发明的较佳实施例中，用聚苯乙烯模具形成伊泰菲康(etafilcon)A，一种含水58％的水凝胶隐形眼镜，该聚苯乙烯的表面能为每厘米40达因。从实验已经证明伊泰菲康A材料的预聚合物(与硼酸酯稀释剂结合以在背景部分中所述的各专利中所述的模制期间代替水)在与聚苯乙烯表面接触时，有包括28度至30度之间的接触角。
增加聚苯乙烯和其他塑料的表面能的方法，包括火焰处理、等离子和化学刻蚀、及电表面处理。最佳实施例中所用的方法为电表面处理，也叫电晕处理。已发现聚合在加速的电子所射向的表面上的单体，结合到了处理后的表面上。特别地，包括甲基丙烯酸羟乙基酯(HEMA)、异丁烯酸(MAA)、甲基丙烯酸乙二醇酯(EGDMA)及三羟甲基丙烷三甲基丙烯酸酯(TMPTMA)的混合物的单体，当聚合成离子的、含水58％的、被称为伊泰菲康A的第Ⅳ组水凝胶聚合物时，将附着在由高质量的聚苯乙烯制作的模具表面上；在此聚苯乙烯的表面上，通过电晕处理投射了加速电子。一般认为，这种效应是由使氧电离的电子间接产生的，电离的氧随即与聚合物模具相互作用。
在实现此方法中，一装置包括与需要处理的区域相符的一组电极、高压变压器和带有阻抗匹配电子线路的高频发生器。在从14至50KV运行时，根据阻抗调节操作频率至25KHz。借助这种高频和高电压的组合，可维持约3.81cm的间距，并通过在电极间维持较强的等离子体来维持较短的处理时间。
在处理后，上述伊泰菲康A单体与聚苯乙烯之间的接触角为6°至12°之间。这相当于聚苯乙烯中表面能增至65至70达因/厘米。
参见图2，其中显示了一个特定实施例，用于在根据背景部分中的参考文献构成的聚苯乙烯模具上实施本发明。在此图中，显示了用于处理的凸阳模具20。此阳模具20被用模具支撑件22固定。此模具支撑件由诸如聚(对苯二酸亚乙酯)的非导电材料制作，并大致为筒形。在模具支撑件22的外部有电极24，该电极24靠近但不接触模件20。
反电极26大致位于阳模具20与电极24相对的一侧。此反电极也大体为筒形，但有中空的内部。此反电极与阳模件20的凸缘区相接触，并有延伸到模具附近的内部凸表面的表面，但不接触与电极24的位置大致相对的阳模件的后表面。
这形成了如28所示的处理区。
电极与处理区的间距，在0.0至0.127cm之间，而在处理区中反电极与阳模具20的后表面之间的区域在0(接触)至约0.19cm之间。
参见图3，其中显示了在用于处理多个模具的组件中的多个电极和反电极。如图2所示，这里也显示了模具件支撑件22、电极24及反电极26。未显示用于处理的模具件。
此图也显示了在装置中向电极22提供共用电压的电极板30及连到安装板34的绝缘支座32。反电极26由支架36支撑，且组件骑跨在导杆38上。借助导杆38的移动，支架36可使反电极26离开电极24和模具支撑件22，从而便于模具的插入和移去。
在进行实际处理时，电极被置于距待处理的模具表面0.25mm至0.5mm处。
虽然不知道使聚合材料附着于电晕处理过的聚苯乙烯的准确机理，理论上已把电表面处理效应与诸如消蚀(表面退化)、聚合物交连、氧化、氢接合及驻极体形成相联系。虽然该机理尚不清楚，已发现影响聚苯乙烯和透镜聚合物之间的附着强度的一个参数，是在模具表面处理之前和期间存在的氧的量。一般，氧的水平越低，氧对表面的附着就越低，聚苯乙烯和透镜聚合物之间的附着就越小。因此，在处理前应尽量减小氧与聚苯乙烯模具的接触。
影响附着强度的其他参量，是电极的功率、处理时间、及处理频率和电压。
对于本发明，已发现，处理电压为10kv，频率在20KHz至30KHz、功率在10瓦至80瓦-最好为30瓦、且持续时间至少为0.2秒，会给出最好的效果。在最佳实施例中，其中电极直径为2cm、
功率为22瓦且处理“时间”为在外界环境中0.3秒，100％的飞边被用凸阳模具除去，而且仅有0.5％的透镜被不适当地被凸阳模件20所滞留。
参见图4，其中显示了包括凹阴模具40的配合的模具件。在合起的一对模具之间，是透镜42；且在透镜的外部，在周边上且在模具20和40的凸缘之间，是飞边44受到电晕处理的区域相对于透镜和飞边的位置，现在可看得很明显。
如本领域的人员所能理解的，这些参数中任一个的过份增大，都会使处理进入凸阳模具件的透镜表面，造成透镜对阳模具件的附着。
已发现，若在电极向目标表面放电期间没有氧的存在，则延长的处理时间或更高的功率都不会使飞边附着于目标表面。简言之，据信电晕处理使氧电离并结合到凸模具件的特定区域，从而以化学方式改变了表面。
在处理和填入单体后，用造成聚合作用的化学、热或紫外手段使单体聚合。在聚合完成后，把阳和阴模具件部分分开，并取出透镜。

Claims (9)

1．一种将模制的眼用透镜分离出来的方法，模制所使用的模具由至少两部分组成：一个阴的凹模部分和一个阳的凸模部分，两部分拼合在一起时，两者之间形成一个空腔，至少一个部分的周边形成有凸缘，将所述空腔中的镜片材料与模具空腔外面环绕着镜片的多余材料分开，所述方法的特征在于，它包括下列步骤：
向一个模具凸缘表面的至少一部分上提供加速电子，以提高其表面能；
向所述模具的阴的凹模部分中充入单体；
将模具的阳的凸模部分拼合到充有单体的阴的凹模部分上，并排出模具空腔中多余的单体，并使单体与具有所述提高了表面能的凸缘表面接触，使所述单体聚合；和
将镜片从带凸缘的模具部分取出，同时保留所述表面能提高的凸缘表面上经聚合的多余单体，从而将两模具部分分开。
2．根据权利要求1的方法，其特征为向模具表面提供加速电子是通过向模具之一施加电晕场来实现的。
3．根据权利要求2的方法，其特征为所述电晕场引起氧电离并使凸模表面暴露给电离的氧。
4．根据权利要求3的方法，其特征为所述电晕场是通过两个电极间产生的放电而被加到模件之一上的。
5．根据权利要求4的方法，其特征为所加的所述电晕场的功率为10瓦～80瓦。
6．根据权利要求1的方法，其特征为用单体填注所述模具的阴的凹模件包括填注甲基丙烯酸羟乙基酯(HEMA)、异丁烯酸(MAA)甲基丙烯酸乙二醇酯(EGDMA)及三羟甲基丙烷三甲基丙烯酸酯(TMPTMA)的混合物。
7．根据权利要求5的方法，其特征为电晕场的施加时间为至少0.2秒。
8．一种眼用透镜模具处理设备，所述模具由至少两部分组成：一个阴的凹模具部分和一个阳的凸模具部分，两部分拼合在一起时，两者之间形成一个空腔，至少一个部分的周边因模具空腔外面围绕镜片的任何多余材料而形成有凸缘，所述处理是通过优先给经处理的模具部分保留飞边使镜片从带飞边的相应模具部分分离出来，所述设备的特征在于，它包括：
第一电极，用于提供经加速的电子；
第二电极，用于将所述电子引向至少一个模具部分表面的凸缘部分并偏离模具部分形成空腔部分。
9．根据权利要求8所述的装置，其特征在于，所述电源的电压为10KV电压，频率为20KHz-30KHz。
CN93112966A 1992-12-21 1993-12-21 眼用透镜模具的处理方法及装置 Expired - Lifetime CN1073011C (zh)

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