CN112513114B - 超高dk材料 - Google Patents

超高dk材料 Download PDF

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CN112513114B
CN112513114B CN201880096082.0A CN201880096082A CN112513114B CN 112513114 B CN112513114 B CN 112513114B CN 201880096082 A CN201880096082 A CN 201880096082A CN 112513114 B CN112513114 B CN 112513114B
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詹姆斯·A·小博纳菲尼
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Abstract

一种生产超高Dk材料的方法,包括使以下物质接触并反应:甲基丙烯酸氟代烷基酯;烷基二醇二甲基丙烯酸酯;亲水剂,例如甲基丙烯酸;羟烷基三(三甲基硅烷氧基)硅烷;羟烷基封端的聚二甲基硅氧烷;和苯乙烯基乙基三(三甲基硅烷氧基)硅烷;所述反应在惰性气氛中在至少25磅/平方英寸(PSI)的压力下和在足以产生超高Dk材料的温度下进行一段时间。

Description

超高DK材料
技术领域
本发明涉及超高透气性(Dk)材料及其方法;更特别地涉及Dk值大于175的超高Dk材料;并且仍更特别地涉及适合用作刚性透气隐形眼镜的超高Dk。
背景技术
最初,刚性隐形眼镜由聚(甲基丙烯酸甲酯)构成并且不透氧。结果,这种镜片的配戴者很快就抱怨由于角膜缺氧而导致的眼疲劳和眼损伤。因此,隐形眼镜科学发展形成了基于有机硅的隐形眼镜,包括刚性透气(RGP)隐形眼镜。尽管RGP隐形眼镜确实具有一定程度的透氧性(Dk值为30-70,有些则高达140-145),但随着时间的发展,配戴者仍会继续出现眼疲劳和眼损伤的现象。当佩戴时间增加时,由于角膜缺氧,疲劳和损伤仍然是问题。因此,需要一种具有超高透氧性(Dk值大于175)的适合用作RGP镜片的材料。
用于有氧角膜代谢的氧气主要来自大气。因此,在透气的软性或刚性隐形眼镜的佩戴过程中,角膜的生理完整性被认为主要取决于通过镜片的氧气的消耗。因此,对眼睛上的隐形眼镜的生理性能的预测需要一个可以估计氧气通过镜片的指数。
1971年,Fatt和St.Helen将菲克定律(Fick’s Law)应用于氧气通过隐形眼镜的问题,从而将透氧量(Dk/t)的概念引入了该领域。这种台式(bench-top)测量已被广泛用作比较隐形眼镜的基础。但是,正如Fatt所指出的那样,Dk/t术语本身用作衡量镜片性能的标准“令人失望”。Dk/t系数表示氧气可以通过镜片扩散的“容易”程度的度量;但是,在给定情况下,氧气通过隐形眼镜也取决于穿过镜片的驱动力,即分压差。氧气通量(j)是在给定时间内通过镜片单位面积的氧气量的真实指数。
发明内容
根据本发明的一个方面,一种生产超高Dk材料的方法包括使以下物质接触并反应:甲基丙烯酸氟代烷基酯;烷基二醇二甲基丙烯酸酯;亲水剂,例如甲基丙烯酸;羟烷基三(三甲基硅烷氧基)硅烷(hydroxyalkyl tris(trimethylsiloxy)silane);羟烷基封端的聚二甲基硅氧烷;和苯乙烯基乙基三(三甲基硅烷氧基)硅烷。该反应在惰性气氛中在至少25磅/平方英寸(PSI)的压力下,并在足以产生超高Dk材料的温度下进行一段时间。例如,甲基丙烯酸氟代烷基酯可以为甲基丙烯酸六氟异丙酯;烷基二醇二甲基丙烯酸酯可以为新戊二醇二甲基丙烯酸酯;羟烷基三(三甲基硅烷氧基)硅烷可以为3-甲基丙烯酰氧丙基三(三甲基硅烷氧基)硅烷;羟烷基封端的聚二甲基硅氧烷可以为4-甲基丙烯酰氧基丁基封端的聚二甲基硅氧烷(4-methacryloxybutyl terminated polydimethylsiloxane)。苯乙烯基乙基三(三甲基硅烷氧基)硅烷可以占材料的14重量%。所得材料的Dk值大于175。
根据本发明的一个方面,该反应在氮气、氩气或氦气气氛下进行,并且在25psi至1000psi(磅每平方英寸)之间进行。该反应可以在恒温控制的烘箱中进行。反应温度可以为室温(20℃-25℃)或高温,例如高达约50℃。烘箱也可以是可编程的,以允许在反应过程中进行可变的温度控制。反应进一步在容器内进行,其中超高Dk材料形成容器形状。一方面,高Dk材料形成为坯料或棒材。该容器可以由可渗透包括惰性气氛的惰性气体的容器材料构成,例如聚丙烯或聚四氟乙烯。
具体实施方式
在高压下进行合适的单体试剂的聚合可以产生与在环境压力下进行反应相比具有更高透氧性的聚合材料。当使用具有高氧亲合力的起始单体时,透氧性的增加甚至会更明显。结果,可以生产具有超高Dk值的材料。如本文所用,术语“超高Dk”是指Dk值大于175的材料。为此,根据本发明的聚合反应在室温下在恒温控制烘箱内在高压(至少25psi)下进行。“室温”可以是20℃至25℃之间的任意值。根据本发明的另一方面,聚合反应可以在高于25psi,包括高达约1000psi的压力,和/或更高的温度,例如高达约50℃的条件下进行。随着反应压力的增加,可以实现更高的透氧性。此外,聚合反应应在惰性气氛中进行,例如但不限于氮气、氦气和/或氩气气氛。不受任何特定理论的束缚,据认为,超高Dk聚合物材料形成为干凝胶或类干凝胶材料。进一步认为,惰性气体起溶剂的作用,一旦形成聚合物网络,惰性气体就被周围的气体代替,从而形成微孔结构。在本发明的另一方面,可以在超临界流体条件下生产超高Dk聚合物材料。因此认为,通过使用特定的单体和交联剂获得的聚合物网络的刚性防止了微孔结构的塌陷。
根据本发明的一个方面,表1示出了一种非限制性的示例性超高Dk配方:
表1
应当指出,在高压(至少25psi)下结合聚合的苯乙烯基乙基三(三甲基硅烷氧基)硅烷的重量百分比(7%至20%,更特别地为14%)对于生产超高Dk材料是至关重要的。据认为,苯乙烯基乙基三(三甲基硅烷氧基)硅烷有助于产生高自由体积结构,并且与3-甲基丙烯酰氧丙基三(三甲基硅烷氧基)硅烷具有协同作用。
根据本发明的另一方面,一种生产超高Dk材料的方法包括使以下物质接触并反应:甲基丙烯酸氟代烷基酯;烷基二醇二甲基丙烯酸酯;亲水剂,例如甲基丙烯酸;羟烷基三(三甲基硅烷氧基)硅烷;羟烷基封端的聚二甲基硅氧烷;和苯乙烯基乙基三(三甲基硅烷氧基)硅烷。例如但不局限于此,所述甲基丙烯酸氟代烷基酯可以是甲基丙烯酸六氟异丙酯;烷基二醇二甲基丙烯酸酯可以是新戊二醇二甲基丙烯酸酯;羟烷基三(三甲基硅烷氧基)硅烷可以是3-甲基丙烯酰氧丙基三(三甲基硅烷氧基)硅烷;羟烷基封端的聚二甲基硅氧烷可以是4-甲基丙烯酰氧基丁基封端的聚二甲基硅氧烷。该反应在惰性气氛(例如氮气、氩气或氦气)中,在至少25psi的压力下和在足以产生超高Dk材料的温度下进行一段时间。如上所述,该反应可以在室温下,例如在约20℃至约25℃之间,或在升高的温度下,例如高达约50℃,在约25psi至约1000psi的压力下进行。结果,超高Dk材料的Dk值可以大于175,在更高的压力下进行的反应产生具有更高Dk值的材料。另外,根据本发明的超高Dk材料可以具有相对较低的硅含量,从而避免了高硅透气性材料遇到的表面润湿问题。结果,根据本发明生产的超高Dk材料不需要表面处理,例如等离子体处理。
聚合反应可以在容器中进行,其中内部尺寸和几何形状对应于超高Dk材料的所需尺寸和形状。即,超高Dk材料将在容器内以容器空间的形状聚合。该容器可以由诸如聚丙烯或聚四氟乙烯(PTFE)之类的材料构成,该材料可渗透包括惰性气氛的惰性气体。根据本发明的一个方面,该容器可以放在设定为特定温度例如20℃至50℃之间的恒温控制的烘箱中,或者该烘箱可以是可编程的以便允许具有可变温度特性的反应。
例如,根据本发明的一个方面生产的超高Dk材料可用于制造刚性透气(RGP)隐形眼镜。在该非限制性示例中,高Dk材料可以形成直径为约7mm至28mm的镜片、坯料或棒材。坯料的高度可以为约2mm至约15mm,而棒材可以具有任何期望的高度。棒材或坯料的直径可以根据其预期用途进行选择。例如,传统的RGP隐形眼镜的直径为约7mm至约12mm(通常为9mm至10mm),而巩膜(scleral)镜片的直径为约14mm至约24mm(通常为15mm至20mm)。如本领域中已知的,然后可以通过车床加工使超高Dk材料的坯料和棒材成形以产生期望的镜片。或者,可以在所述条件下直接铸造镜片。
尽管已经参考本发明的优选实施例对本发明进行了描述,但是应当理解,在不脱离由所附权利要求所限定的本发明的全部精神和范围的情况下,可以对其做出各种修改。

Claims (11)

1.一种生产超高Dk材料的方法,包括使以下物质接触并反应:
a)甲基丙烯酸氟代烷基酯;
b)烷基二醇二甲基丙烯酸酯;
c)亲水剂;
d)羟烷基三(三甲基硅烷氧基)硅烷;
e)羟烷基封端的聚二甲基硅氧烷;和
f)苯乙烯基乙基三(三甲基硅烷氧基)硅烷,
所述反应在惰性气氛中在至少25磅/平方英寸的压力下和在足以产生超高Dk材料的温度下进行一段时间;
所述羟烷基三(三甲基硅烷氧基)硅烷为3-甲基丙烯酰氧丙基三(三甲基硅烷氧基)硅烷;
所述亲水剂为甲基丙烯酸;
所述苯乙烯基乙基三(三甲基硅烷氧基)硅烷占材料的7重量%至20重量%;
所述材料的Dk值大于175;
所述反应在室温下进行,或者所述反应在高于室温下进行。
2.根据权利要求1所述的方法,其中所述甲基丙烯酸氟代烷基酯为甲基丙烯酸六氟异丙酯;所述烷基二醇二甲基丙烯酸酯为新戊二醇二甲基丙烯酸酯;所述羟烷基封端的聚二甲基硅氧烷为4-甲基丙烯酰氧基丁基封端的聚二甲基硅氧烷。
3.根据权利要求2所述的方法,其中所述苯乙烯基乙基三(三甲基硅烷氧基)硅烷占材料的14重量%。
4.根据权利要求1所述的方法,其中所述苯乙烯基乙基三(三甲基硅烷氧基)硅烷占所述材料的14重量%。
5.根据权利要求1所述的方法,其中所述反应在氮气、氩气或氦气气氛下进行。
6.根据权利要求1所述的方法,其中所述反应在25psi至1000psi之间进行。
7.根据权利要求1所述的方法,其中所述反应在容器中进行,所述超高Dk材料在容器中形成为所述容器的形状。
8.根据权利要求7所述的方法,其中选择容器,由此使高Dk材料形成为镜片、坯料或棒材。
9.根据权利要求7所述的方法,其中所述容器由能渗透包括惰性气氛的惰性气体的容器材料构成。
10.根据权利要求9所述的方法,其中所述容器由聚丙烯或聚四氟乙烯构成。
11.一种超高Dk材料,其根据权利要求1所述的方法生产。
CN201880096082.0A 2018-06-28 2018-06-28 超高dk材料 Active CN112513114B (zh)

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