RU2776463C2 - Ophthalmic devices obtained from grafted polymer meshes and their production and application methods - Google Patents

Abstract

FIELD: ophthalmology.

SUBSTANCE: invention relates to ophthalmic devices, such as contact lenses. The ophthalmic device is formed by a method including: (a) provision of the first reactive composition containing: (i) a polymerization initiator, which is capable of forming upon first activation two or more free radical groups, at least one of which can additionally be activated upon subsequent activation; (ii) one or more ethylene unsaturated compounds; and (iii) a cross-linking agent; (b) exposure of the first reactive composition to the first activation stage, so that the first reactive composition is polymerized at it to form a cross-linked substrate mesh containing a covalently bound activated initiator of free radical polymerization; (c) bringing into contact of the cross-linked substrate mesh with a graft composition containing one or more ethylene unsaturated compounds, wherein bringing into contact is carried out under such conditions that the graft composition penetrates the cross-linked substrate mesh and is more concentrated on the surface of the cross-linked substrate mesh than in the core; and (d) activation of the covalently bound activated initiator of free radical polymerization in the cross-linked substrate mesh in such a way that the graft composition is polymerized at this point with the cross-linked substrate mesh.

EFFECT: invention provides an improvement in the quality of manufacture of a device.

34 cl, 16 tbl

Description

Related Applications

This application claims priority over U.S. Provisional Application No. 16/239,595, filed January 4, 2019, and U.S. Provisional Application No. 62/623,781, filed January 30, 2018, each of which is hereby incorporated by reference in its entirety. .

Scope of the invention

The invention relates to ophthalmic devices, such as contact lenses, which contain grafted polymer networks, and to methods for making and using ophthalmic devices.

Prerequisites for the creation of the invention

The development of polymeric materials derived from individual components that provide desirable properties is a current goal in many product areas. For example, polymeric materials exhibiting oxygen permeability and hydrophilicity are desirable for a number of medical device applications such as ophthalmic devices.

A frequently encountered problem in the formation of polymeric materials that attempt to combine properties is that in many cases the individual components from which the final material is derived are not readily compatible. For example, in the area of contact lenses, silicone hydrogels have been found to provide lenses with significantly increased oxygen permeability and therefore are able to reduce corneal edema and hypervasculature, conditions that can sometimes be associated with conventional hydrogel lenses. Silicone hydrogels are typically prepared by polymerization of mixtures containing at least one silicone-containing monomer and at least one hydrophilic monomer. However, silicone hydrogel lenses can be difficult to manufacture because silicone components and hydrophilic components are often incompatible.

New technologies for creating polymeric materials are desirable in many areas, including ophthalmic devices.

Statement of the Invention

The invention relates to new polymeric compositions obtained from a wide range of components - monomers and polymers, including cases where such components (monomers and polymers) are essentially incompatible. Such polymeric compositions find use in various fields, for example in ophthalmic devices.

Thus, in one aspect, the invention provides an ophthalmic device formed by a method comprising:

(a) providing a first reactive composition comprising: (i) a polymerization initiator which is capable, upon first activation, of forming two or more free radical groups, at least one of which may be further activated upon subsequent activation; (ii) one or more ethylenically unsaturated compounds; and (iii) a cross-linking agent;

(b) subjecting the first reactive composition to a first activation step such that the first reactive composition polymerizes thereon to form a cross-linked substrate network containing a covalently bound, activated free radical polymerization initiator;

(c) contacting the cross-linked substrate network with a grafting composition containing one or more ethylenically unsaturated compounds, wherein the contacting is carried out under such conditions that the grafting composition penetrates the cross-linked substrate network and is more concentrated on the surface transversely -crosslinked substrate network than in the core; and

(d) activating a covalently bound, activated free radical polymerization initiator at the cross-linked substrate network such that the graft composition polymerizes at that location with the cross-linked substrate network.

In another aspect, the invention provides an ophthalmic device made from a reaction product of a composition comprising: (i) a cross-linked substrate network containing covalently linked, activated free radical polymerization initiators; and (ii) a graft composition containing one or more ethylenically unsaturated compounds.

In a further aspect, the present invention provides a method for producing an ophthalmic device, comprising:

(a) providing a first reactive composition comprising: (i) a polymerization initiator which is capable, upon first activation, of forming two or more free radical groups, at least one of which may be further activated upon subsequent activation; (ii) one or more ethylenically unsaturated compounds; and (iii) a cross-linking agent;

(b) subjecting the first reactive composition to a first activation step such that the first reactive composition polymerizes thereon to form a cross-linked substrate network containing a covalently bound, activated free radical polymerization initiator;

(c) contacting the cross-linked substrate network with a grafting composition containing one or more ethylenically unsaturated compounds, wherein the contacting is carried out under such conditions that the grafting composition penetrates the cross-linked substrate network and is more concentrated on the surface transversely -crosslinked substrate network than in the core; and

(d) activating a covalently bound, activated free radical polymerization initiator at the cross-linked substrate network such that the graft composition polymerizes at that location with the cross-linked substrate network.

Detailed description of the invention

Unless otherwise indicated, all technical and scientific terms used in this document have a generally accepted meaning, understandable to any person skilled in the field to which the invention pertains. All publications, patent applications, patents and other references mentioned in this document are incorporated herein by reference.

Unless otherwise noted, numeric ranges, such as in "from 2 to 10" or as in "between 2 and 10", include the numbers defining the range (eg, 2 and 10).

Unless otherwise indicated, ratios, percentages, fractions, etc. are by weight.

The phrase "number average molecular weight" refers to the number average molecular weight (M _n ) of the sample; the phrase "weight average molecular weight" refers to the weight average molecular weight (M _w ) of the sample; the phrase "polydispersity index" (PDI) refers to the ratio of M _w divided by M _n and describes the molecular weight distribution of the sample. If the type of "molecular weight" is not specified or is not obvious from the context, then it is understood that it refers to the number average molecular weight.

As used herein, the term "about" refers to the range of +/- 10 percent of the number to which it applies. For example, the phrase "about 10" would include both 9 and 11.

As used herein, the term "(meth)" refers to the possible presence of an optional methyl substituent. Thus, the term "(meth)acrylate" refers to both methacrylate and acrylate.

It should be appreciated that wherever chemical structures are given, variants presented as substituents in the structure may be combined in any combination. Thus, if the structure contains substituents R* and R**, each of which has three lists of potential groups, 9 combinations are possible. The same applies to the combination of properties.

The average number of repeat units in a polymer sample is known as the "degree of polymerization". When a general chemical formula of a polymer sample is used, such as [***] _n , "n" refers to its degree of polymerization, and the formula must be interpreted as representing the number average molecular weight of the polymer sample.

As used herein, the term "subject" includes humans and vertebrates.

As used herein, the term "ophthalmic device" refers to any device that is placed in or on the eye or any part of the eye, including the surface of the eye. Such devices may provide optical correction, cosmetic enhancement, vision enhancement, therapeutic effect (eg as a dressing), or delivery of active ingredients such as pharmaceutical and nutraceutical ingredients, or any combination of the above. Examples of ophthalmic devices include, but are not limited to, lenses and optical and ocular inserts, including but not limited to punctal obturators, and the like. The term "lens" includes soft contact lenses, hard contact lenses, hybrid contact lenses, intraocular lenses, and inlay lenses, and masking lenses. The ophthalmic device may be a contact lens.

As used herein, the term "contact lens" refers to an ophthalmic device that can be placed on the cornea of a subject's eye. A contact lens may provide a corrective, cosmetic, or therapeutic benefit, including wound healing, drug or nutraceutical delivery, diagnostic evaluation or monitoring, UV light blocking, visible or glare reduction, or any combination thereof. A contact lens may be made from any suitable material known in the art and may be a soft lens, a hard lens, or a hybrid lens containing at least two distinct parts with different physical, mechanical, or optical properties such as modulus, water content, light transmission, or combinations thereof.

The ophthalmic devices and contact lenses of the invention may be made from silicone hydrogels. Such silicone hydrogels typically contain at least one hydrophilic monomer and at least one silicone-containing component that are covalently bonded to each other in a polymerized device. The ophthalmic devices and contact lenses of the invention can also be made from conventional hydrogels or a combination of conventional and silicone hydrogels.

A "macromolecule" is an organic compound having a number average molecular weight greater than 1500 and may or may not be reactive.

As used herein, the term "target macromolecule" is an intended macromolecule synthesized from a reactive composition containing monomers, macromers, prepolymers, crosslinkers, initiators, additives, diluents, and the like.

As used herein, the term "monomer" is a monofunctional molecule that can undergo chain growth polymerization and, in particular, free radical polymerization, thus creating a repeating unit in the chemical structure of the target macromolecule. Some monomers have bifunctional impurities that can act as crosslinkers. "Hydrophilic monomer" is also a monomer that gives a clear, single-phase solution when mixed with deionized water at 25°C at a concentration of 5 wt%. A “hydrophilic component” is a monomer, macromer, prepolymer, initiator, cross-linker, additive, or polymer that gives a clear, single-phase solution when mixed with deionized water at 25 °C at a concentration of 5% by weight.

As used herein, the term "macromonomer" or "macromer" is a linear or branched macromolecule having at least one polymerizable group that can undergo chain growth polymerization and, in particular, free radical polymerization.

Used in this document, the term "polymerizable" means that the connection contains at least one polymerizable group. "Polymerizable groups" are groups that can undergo chain growth polymerization, such as free radical and/or cationic polymerization, eg a carbon double bond group, that can polymerize when exposed to radical polymerization initiation conditions. Non-limiting examples of polymerizable groups include (meth)acrylates, styrenes, vinyl ethers, (meth)acrylamides, N -vinyl lactams, N -vinyl amides, O-vinyl carbamates, O-vinyl carbonates, and other vinyl groups. The polymerizable groups preferably comprise (meth)acrylates, (meth)acrylamides and mixtures thereof. The polymerizable groups preferably contain (meth)acrylate, (meth)acrylamide, N-vinyl lactam, N-vinylamide, styryl functional groups, or mixtures of any of the above. The polymerizable group may be substituted or unsubstituted. For example, the nitrogen atom in (meth)acrylamide may be bonded to a hydrogen, or the hydrogen may be substituted with alkyl or cycloalkyl (which may themselves be further substituted). Unlike the term "polymerizable", the term "non-polymerizable" means that the compound does not contain such a free radical polymerizable group.

Examples of the above groups include substituted or unsubstituted C _1-6 alkyl(meth)acrylates, C _1-6 alkyl(meth)acrylamides, C _2-12 alkenyls, C _2-12 alkenylphenyls, C _2-12 alkenylnaphthyls, C _{2- 6} alkenylphenyl-C _1-6 alkyls in which acceptable substituents on said C _1-6 alkyls include ethers, hydroxyls, carboxyls, halogens, and combinations thereof.

Any type of free radical polymerization can be used, including, but not limited to, mass, solution, suspension, and emulsion, as well as any controlled radical polymerization methods such as stable free radical initiated polymerization, nitroxide-mediated living polymerization, atom transfer radical polymerization, polymerization by reversible addition and fragmentation, organotellurium mediated living radical polymerization, etc.

An "ethylenically unsaturated compound" is a monomer, macromer, or prepolymer that contains at least one polymerizable group. The ethylenically unsaturated compound may preferably consist of a single polymerizable group.

As used herein, the term "silicone-containing component" or "silicone component" is a monomer, macromer, prepolymer, crosslinker, initiator, additive, or polymer in a reactive composition with at least one silicon-oxygen bond, usually in the form of siloxy groups, siloxane groups, carbosiloxane groups and mixtures thereof. Примеры силиконсодержащих компонентов, которые применяют в настоящем изобретении, можно найти в патентах США № 3,808,178, 4,120,570, 4,136,250, 4,153,641, 4,740,533, 5,034,461, 5,070,215, 5,244,981, 5,314,960, 5,331,067, 5,371,147, 5,760,100, 5,849,811, 5,962,548, 5,965,631, 5,998,498, 6,367,929, 6,822,016, 6,943,203, 6,951,894, 7,052,131, 7,247,692, 7,396,890, 7,461,937, 7,468,398, 7,538,146, 7,553,880, 7,572,841, 7,666,921, 7,691,916, 7,786,185, 7,825,170, 7,915,323, 7,994,356, 8,022,158, 8,163,206, 8,273,802, 8,399,538, 8,415,404, 8,420,711, 8,450,387, 8,487,058, 8,568,626, 8,937,110, 8,937,111, 8,940,812, 8,980,972, 9,056,878, 9,125,808, 9,140,825, 9,156,934, 9,170,349, 9,217,813, 9,244,196, 9,244,197, 9,260,544, 9,297,928, 9,297,929 и европейском патенте № 080539. Указанные патенты настоящим полностью включены путем ссылки.

"Polymer" is a target macromolecule consisting of repeating units of monomers and macromers used during polymerization.

"Homopolymer" is a polymer derived from a single monomer; "copolymer" is a polymer derived from two or more monomers; "terpolymer" is a polymer derived from three monomers. "Block copolymer" consists of blocks or segments of different composition. Diblock copolymers have two blocks. Triblock copolymers have three blocks. "Comb copolymers" or "graft copolymers" consist of at least one macromer.

A "repeating unit" is the smallest group of atoms in a polymer that corresponds to the polymerization of a particular monomer or macromer.

An "initiator" is a molecule that can decompose into free radical groups that can react with a monomer to initiate a free radical polymerization reaction. The thermal initiator decomposes at a certain rate depending on the temperature; typical examples are azo compounds such as 1,1'-azobisisobutyronitrile and 4,4'-aobis(4-cyanovaleric acid), peroxides such as benzoyl peroxide, t-butyl peroxide, t-butyl hydroperoxide, t-butyl peroxybenzoate, dicumyl peroxide and lauroyl peroxide, peroxyacids such as peracetic acid and potassium persulfate, as well as a variety of redox systems. The photoinitiator is degraded by a photochemical process; typical examples are derivatives of benzyl, benzoin, acetophenone, benzophenone, camphorquinone and mixtures thereof, as well as various monoacyl and bisacyl phosphine oxides and combinations thereof.

A "free radical group" is a molecule that has an unpaired valence electron that can react with a polymerizable group to initiate a free radical polymerization reaction.

A "crosslinker" or "crosslinker" is a bifunctional or multifunctional monomer that can undergo free radical polymerization at two or more sites in a molecule, thereby creating branch points and forming a polymer network. The two or more polymerizable functional groups of the cross-linking agent may be the same or different and, for example, may be independently selected from vinyl groups (including allyl), (meth)acrylate groups, and (meth)acrylamide groups. Common examples include ethylene glycol dimethacrylate, tetraethylene glycol dimethacrylate, trimethylol propane trimethacrylate, methylene bisacrylamide, triallyl cyanurate, and the like.

A "prepolymer" is a reaction product of monomers (or macromers) that contains remaining polymerizable groups capable of being further reacted to form a polymer.

A "polymer network" is a type of polymer that is in the form of a cross-linked macromolecule. As such, the polymer network can swell but cannot dissolve in solvents. For example, the cross-linked substrate network of the invention is a material that can swell without dissolving.

"Hydrogels" are polymer networks that swell in water or aqueous solutions, typically absorbing at least 10 wt. water (at 25 °C). "Silicone hydrogels" are hydrogels that are made from at least one silicone-containing component with at least one hydrophilic component. Hydrophilic components may also include non-reactive polymers.

"Conventional hydrogels" refers to polymeric networks derived from monomers without any siloxy, siloxane, or carbosiloxane groups. Conventional hydrogels are prepared from reaction compositions predominantly containing hydrophilic monomers such as 2-hydroxyethyl methacrylate (HEMA), N-vinylpyrrolidone (NVP), N,N-dimethylacrylamide (DMA), or vinyl acetate.

As used herein, the term "reactive composition" refers to a composition containing one or more reactive components (and optionally non-reactive components) that are mixed (when more than one is present) together and, when subjected to polymerization conditions, form polymeric compositions. If more than one component is present, the reactive composition may also be referred to herein as "reaction mixture" or "reactive monomer mixture" (or RMM). The reactive composition contains reactive components such as monomers, macromers, prepolymers, crosslinkers and initiators, and optional additives such as wetting agents, separating agents, dyes, light absorbing compounds such as UV visible absorbers, pigments, dyes and photochromic compounds. , any of which may be reactive or non-reactive, but preferably capable of being retained in the resulting polymer composition, as well as pharmaceutical and nutraceutical compounds and any diluents. It should be understood that a wide range of additives may be added depending on the end product that is obtained and its intended use. The concentrations of the components of the reactive composition are expressed as the weight percentage of all components of the reactive composition, with the exception of the diluent. When diluents are used, their concentrations are expressed as weight percentages based on the amount of all components in the reactive composition and the diluent.

"Reactive components" are components in a reactive composition that become part of the chemical structure of the resulting material through covalent bonding, hydrogen bonding, electrostatic interactions, formation of interpenetrating polymer networks, or any other means. Examples include, without limitation, silicone-containing reactive components (eg, silicone-containing components, described below) and hydrophilic reactive components (eg, hydrophilic monomers, described below).

As used herein, the term "silicone hydrogel contact lens" refers to a contact lens containing at least one silicone hydrogel. Silicone hydrogel contact lenses essentially have increased oxygen permeability compared to conventional hydrogels. To transfer oxygen to the eye, silicone hydrogel contact lenses use both their water and polymer components.

The term "multifunctional" refers to a component having two or more polymerizable groups. The term "monofunctional" refers to a component having a single polymerizable group.

The terms "halogen" or "halo" refer to fluorine, chlorine, bromine and iodine.

As used herein, the term "alkyl" refers to an unsubstituted or substituted linear or branched alkyl group containing the indicated number of carbon atoms. If the number is not specified, then alkyl (optionally including any substituents on alkyl) may contain from 1 to 16 carbon atoms. The alkyl group preferably contains 1 to 10 carbon atoms, alternatively 1 to 7 carbon atoms, or alternatively 1 to 4 carbon atoms. Examples of alkyl include methyl, ethyl, propyl, isopropyl, butyl, iso-, sec-, and tert-butyl, pentyl, hexyl, heptyl, 3-ethylbutyl, and the like. Examples of substituents on the alkyl group include 1, 2 or 3 groups independently selected from hydroxy, amino, amido, oxa, carboxy, alkylcarboxy, carbonyl, alkoxy, amido, carbamate, carbonate, halogen, phenyl, benzyl, and combinations thereof. "Alkylene" means a divalent alkyl group such as -CH ₂ -, -CH ₂ CH ₂ -, -CH ₂ CH ₂ CH ₂ -, -CH ₂ CH(CH ₃ )CH ₂ - and -CH ₂ CH ₂ CH _{2 CH2-} .

The term "haloalkyl" refers to an alkyl group as defined above which is substituted by one or more halogen atoms, where each halogen is independently F, Cl, Br, or I. Preferred halogen is F. Preferred haloalkyl groups contain 1-6 carbon atoms , more preferably 1-4 carbon atoms and even more preferably 1-2 carbon atoms. The term "haloalkyl" includes perhaloalkyl groups such as -CF ₃ - or -CF ₂ CF ₃ -. The term "haloalkylene" means a divalent haloalkyl group such as -CH ₂ CF ₂ -.

The term "cycloalkyl" refers to an unsubstituted or substituted cyclic hydrocarbon containing the specified number of carbon atoms in the ring. If the number is not specified, then cycloalkyl may contain from 3 to 12 carbon atoms in the ring. Preferred are C ₃ -C ₈ cycloalkyl, more preferably C ₄ -C ₇ cycloalkyl, and even more preferably C ₅ -C ₆ cycloalkyl. Examples of cycloalkyl groups include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, and cyclooctyl. Examples of substituents on the cycloalkyl group include 1, 2 or 3 groups independently selected from alkyl, hydroxy, amino, amido, oxa, carbonyl, alkoxy, amido, carbamate, carbonate, halogen, phenyl, benzyl, and combinations thereof. The term "cycloalkylene" means a divalent cycloalkyl group such as 1,2-cyclohexylene, 1,3-cyclohexylene or 1,4-cyclohexylene.

The term "heterocycloalkyl" refers to a cycloalkyl ring or ring system as defined above in which at least one carbon in the ring is replaced by a heteroatom selected from nitrogen, oxygen and sulfur. The heterocycloalkyl ring is optionally fused or otherwise connected to other heterocycloalkyl rings and/or non-aromatic hydrocarbon rings and/or phenyl rings. Preferred heterocycloalkyl groups have 5 to 7 members. More preferred heterocycloalkyl groups have 5 to 6 members. The term "heterocycloalkyl" means a divalent heterocycloalkyl group.

The term "aryl" refers to an unsubstituted or substituted aromatic hydrocarbon ring system containing at least one aromatic ring. The aryl group contains the indicated number of carbon atoms in the ring. If the number is not specified, aryl may contain from 6 to 14 carbon atoms in the ring. The aromatic ring may optionally be fused or otherwise attached to other aromatic hydrocarbon rings or non-aromatic hydrocarbon rings. Examples of aryl groups include phenyl, naphthyl and biphenyl. Preferred examples of aryl groups include phenyl. Examples of substituents on the aryl group include 1, 2, or 3 groups independently selected from alkyl, hydroxy, amino, amido, oxa, carboxy, alkylcarboxy, carbonyl, alkoxy, amido, carbamate, carbonate, halogen, phenyl, benzyl, and combinations thereof. . The term "arylene" means a divalent aryl group, such as 1,2-phenylene, 1,3-phenylene or 1,4-phenylene.

The term "heteroaryl" refers to an aryl ring or ring system as defined above in which at least one carbon atom in the ring is replaced by a heteroatom selected from nitrogen, oxygen and sulfur. The heteroaryl ring may be fused or otherwise attached to one or more heteroaryl rings, aromatic or non-aromatic hydrocarbon rings, or heterocycloalkyl rings. Examples of heteroaryl groups include pyridyl, furyl, and thienyl. The term "heteroarylene" means a divalent heteroaryl group.

The term "alkoxy" means an alkyl group attached to the original fragment of the molecule through an oxygen bridge. Examples of alkoxy groups include, for example, methoxy, ethoxy, propoxy and isopropoxy. The term "aryloxy" means an aryl group attached to the original fragment of the molecule through an oxygen bridge. Examples include phenoxy. The term "cyclic alkoxy group" means a cycloalkyl group attached to the original fragment through an oxygen bridge.

The term "alkylamine" refers to an alkyl group attached to the original fragment of the molecule through the bridge -NH. The term "alkyleneamine" means a divalent alkylamine group such as -CH ₂ CH ₂ NH-.

The term "siloxanil" refers to a structure having at least one Si-O-Si bond. Thus, for example, a siloxanyl group means a group having at least one Si-O-Si group (ie, a siloxane group), and a siloxanyl compound means a compound having at least one Si-O-Si group. The term "siloxanil" embraces monomeric (eg Si-O-Si) as well as oligomeric/polymeric structures (eg -[Si-O] _n - where n is 2 or more). Each silicon atom in the siloxanyl group is substituted with independently selected groups R ^A (where R ^A is defined as indicated in (b)-(i) of formula A) to fill the valency.

The term "silyl" refers to a structure of formula R ₃ Si- and "siloxy" refers to a structure of formula R ₃ Si-O-, where each R in silyl or siloxy is independently selected from trimethylsiloxy, C ₁ -C ₈ alkyl (preferably C ₁ -C ₃ alkyl, more preferably alkyl or methyl) and C ₃ -C ₈ cycloalkyl.

The term "alkyleneoxy" refers to groups of the general formula -(alkylene-O) _p - or -(O-alkylene) _p -, where alkylene is defined as above and p is from 1 to 200, or from 1 to 100, or 1 to 50, or 1 to 25, or 1 to 20, or 1 to 10, each alkylene being independently optionally substituted with one or more groups independently selected from hydroxyl, halogen (e.g. fluorine), amino, amido, ether, carbonyl, carboxyl, and combinations thereof. If p is greater than 1, then all alkylenes may be the same or different, and alkyleneoxy may have a block or random configuration. If the alkyleneoxy forms an end group in the molecule, the alkyleneoxy end may, for example, be hydroxy or alkoxy (eg HO-[CH ₂ CH ₂ O] _p - or CH ₃ O-[CH ₂ CH ₂ O] _p -). Examples of alkyleneoxy include polymethylenemethoxy, polyethyleneioxy, polypropyleneoxy, polybutyleneoxy, and poly(ethyleneoxy-co-propyleneoxy).

The term "oxaalkylene" refers to an alkylene group, as defined above, in which one or more non-adjacent CH ₂ groups have been replaced by an oxygen atom, eg -CH ₂ CH ₂ OCH(CH ₃ )CH ₂ -. The term "thiaalkylene" refers to an alkylene group, as defined above, in which one or more non-adjacent CH ₂ groups have been replaced by a sulfur atom, eg -CH ₂ CH ₂ SCH(CH ₃ )CH ₂ -.

The term "linking group" refers to a functional group that links the polymerizable group to the original molecule. The linking group may be any functional group that does not undesirably interfere with the polymerization of the compound of which it is a part. For example, the linking group may be a bond or may be one or more of alkylene, haloalkylene, amide, amine, alkyleneamine, carbamate, carboxylate (-CO ₂ -), arylene, heteroarylene, cycloalkylene, heterocycloalkylene, alkyleneoxy, oxaalkylene, thiaalkylene, haloalkyleneoxy (alkyleneoxy substituted with one or more halogen groups, eg —OCF ₂ —, —OCF ₂ CF ₂ —, —OCF ₂ CH ₂ —), siloxanyl, alkylenesiloxanyl, or combinations thereof. The linking group may optionally be substituted with 1 or more groups. Acceptable substituents may include groups independently selected from alkyl, halogen (e.g., fluoro), hydroxyl, HO-alkyleneoxy, MeO-alkyleneoxy, siloxanyl, siloxy, siloxy-alkyleneoxy-, siloxy-alkylene-alkyleneoxy- (in which may be present more than one alkyleneoxy group, and in which each methylene in the alkylene or alkyleneoxy is independently optionally substituted with hydroxyl), an ether, an amine, a carbonyl, a carbamate, and combinations thereof. The linking group may also be substituted with a polymerizable group such as (meth)acrylate.

Preferred linking groups include C ₁ -C ₈ alkylene (preferably C ₂ -C ₆ alkylene) and C ₁ -C ₈ oxaalkylene (preferably C ₂ -C ₆ oxaalkylene), each of which is optionally substituted with 1 or 2 groups, independently selected from hydroxyl and siloxy. Preferred linking groups also include carboxylate, amide, C ₁ -C ₈ alkylene carboxylate-C ₁ -C ₈ alkylene or C ₁ -C ₈ alkylene amide-C ₁ -C ₈ alkylene.

If the linking group consists of combinations of the functional groups described above (eg, alkylene and cycloalkylene), then these functional groups may be present in any order. For example, if in formula E below L is indicated as -alkylene-cycloalkylene-, then Rg-L can be either Rg-alkylene-cycloalkylene- or Rg-cycloalkylene-alkylene-. Despite this, the order of enumeration is the preferred order in which the functional groups appear in the compound, starting with the terminal polymerizable group (Rg) to which the linking group is attached. For example, if in the formula EL and L ² are both alkylene-cycloalkylene, then Rg-L is preferably Rg-alkylene-cycloalkylene-, and -L ² -Rg is preferably -cycloalkylene-alkylene-Rg.

As noted above, in one aspect, the present invention provides an ophthalmic device formed by a method comprising:

(a) providing a first reactive composition comprising: (i) a polymerization initiator which is capable, upon first activation, of forming two or more free radical groups, at least one of which may be further activated upon subsequent activation; (ii) one or more ethylenically unsaturated compounds; and (iii) a cross-linking agent;

(b) subjecting the first reactive composition to a first activation step such that the first reactive composition polymerizes thereon to form a cross-linked substrate network containing a covalently bound, activated free radical polymerization initiator;

(c) contacting the cross-linked substrate network with a grafting composition containing one or more ethylenically unsaturated compounds, wherein the contacting is carried out under such conditions that the grafting composition penetrates the cross-linked substrate network and is more concentrated on the surface transversely -crosslinked substrate network than in the core; and

(d) activating a covalently bound, activated free radical polymerization initiator at the cross-linked substrate network such that the graft composition polymerizes at that location with the cross-linked substrate network.

The polymerization initiator can be any composition capable of generating free radical groups in two or more separate activation steps. In the present invention, there is no particular requirement as to which type of polymerization initiator to use or which activation mechanism, as long as the first activation and the second activation can be carried out sequentially. Thus, suitable polymerization initiators can, for example, be activated by thermal, visible light, ultraviolet light, electron beam irradiation, gamma radiation, or combinations thereof. Examples of polymerization initiators that can be used in the invention include, without limitation, bisacyl phosphine oxides ("BAPOs"), bis(acyl)phosphonoxides (e.g., bis(mesitoyl)phosphinic acid), azo compounds, peroxides, alpha-hydroxy ketones, alpha- alkoxyketones, 1,2-diketones, germanium-based compounds (such as bis(4-methoxybenzoyl)diethylgermanium), or combinations thereof.

BAPO initiators are preferred. Examples of suitable BAPO initiators include, without limitation, compounds having the chemical structure of Formula I:

where Ar ¹ and Ar ² are independently substituted or unsubstituted aryl groups, usually substituted phenyl groups, wherein the substituents are linear, branched or cyclic alkyl groups such as methyl groups, linear, branched or cyclic alkoxy groups such as methoxy groups, and atoms halogen; preferably Ar ¹ and Ar ² have identical chemical structures; and where R ¹ is a linear, branched or cyclic alkyl group having 1 to 10 carbon atoms, or R ¹ is a phenyl group, hydroxyl group or alkoxy group having 1 to 10 carbon atoms.

Can also be used polymerization initiators, activated by different types of energy for the initial and subsequent activations. For example, materials that undergo a first thermal activation and a second activation by irradiation are within the scope of the invention. Examples of such materials with mixed activation include compounds of formulas II, III, IV and V:

where Ar ¹ and Ar ² are independently substituted or unsubstituted aryl groups, usually substituted phenyl groups, wherein the substituents are linear, branched or cyclic alkyl groups such as methyl groups, linear, branched or cyclic alkoxy groups such as methoxy groups, and atoms halogen; preferably Ar ¹ and Ar ² have identical chemical structures; and where R ¹ represents a linear, branched or cyclic alkyl group having from 1 to 10 carbon atoms; where R ² represents a difunctional methylene linking group, which may additionally contain groups of ethers, ketone or ester groups along the methylene chain, having from 1 to 10 carbon atoms; and R ³ represents a hydrogen atom, a hydroxyl group, or a linear, branched or cyclic alkoxy group having 1 to 10 carbon atoms. Another example is tert -butyl-7-methyl-7-( tert -butylazo)peroxyoctanoate.

In addition, diazo compounds, diperoxy compounds or azo peroxy compounds that exhibit two different decomposition temperatures can be used in the present invention.

Preferably, the polymerization initiator is a photopolymerization initiator, preferably a bisacylphosphine oxide. Bisacylphosphine oxides are desirable because they can undergo successive activation steps at different wavelengths and are therefore easy to use. At longer wavelengths, bisacylphosphine oxides can form two free radical groups, one of which is a monoacylphosphine oxide. Subsequently, monacyl phosphine oxide (MAPO) can be subjected to a second activation, usually at a shorter wavelength. A particularly preferred bisacylphosphine oxide is bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide, for which the longer wavelength is typically greater than 420 nm (eg 435 nm and above) and the shorter wavelength is typically 420 nm or less. It may be preferable to use an LED or an equivalent light source where the bandwidths are relatively narrow, thus allowing initial irradiation while retaining some or most of the MAPO groups in the cross-linked substrate network.

Other examples of bisacylphosphine oxide compounds that can be used include bis-(2,6-dimethoxybenzoyl)-2,4,4-trimethylpentylphosphine oxide, bis(2,4,6-trimethylbenzoyl)-2,4,4- trimethylpentylphosphine oxide or bis(2,4,6-trimethylbenzoyl)phosphinic acid or a salt thereof.

In the present invention, a first reactive composition that contains a polymerization initiator, one or more ethylenically unsaturated compounds and a cross-linking agent is subjected to a first activation step under conditions in which the polymerization initiator undergoes its initial activation. For example, if the polymerization initiator is BAPO, the first reactive composition can be irradiated at 435 nm or higher using a suitable light source. The first reactive composition therefore polymerizes to form a cross-linked substrate network. The cross-linked substrate network contains a polymerization initiator moiety as a covalently bound, activated free radical polymerization initiator.

Activation and polymerization of the first reactive composition can be carried out using techniques known to those skilled in the art. For example, the reactive components of the first reactive composition may be mixed in a vessel. A diluent may optionally be used to facilitate mixing. The mixture can be filtered, degassed and heated to the desired temperature, and subsequently irradiated under conditions that cause the first activation of the polymerization initiator and the subsequent formation of a cross-linked substrate network. The polymerization vessel may be a mold for the case where it is desired that the product has a specific shape. For example, the first reactive composition can be dosed and polymerized within the cavity of a pair of molds (eg, front and back molds). The first cross-linked substrate network for use in the ophthalmic devices of the invention is preferably a conventional or silicone hydrogel. More preferably it is a silicone hydrogel.

According to the invention, the cross-linked substrate network formed as described above is contacted with the grafting composition. The graft composition contains one or more ethylenically unsaturated compounds. The cross-linked substrate network is preferably a swellable material to allow it to absorb at least a portion of the grafting composition for the subsequent grafting reaction. Absorption in a cross-linked substrate network can be performed in a variety of ways. For example, a cross-linked substrate network can be placed in the composition for grafting and left to swell. Or, the cross-linked substrate network may first be swollen in a solvent and subsequently combined with the grafting composition, for example, by suspending the pre-swollen cross-linked substrate network in the grafting composition, during which the reactive components are distributed in the cross-linked substrate network by molecular diffusion and fluid exchange. There is no specific minimum amount of graft composition to be absorbed into the cross-linked substrate network, provided that some composition is present (greater than 0% by weight of reactive components). In some embodiments, it may be preferable that the cross-linked substrate network is swellable in the graft composition by at least 0.0001 wt %, alternatively by at least 0.01 wt %, alternatively by at least 0, 1% wt., alternatively at least 5% wt., alternatively at least 10% wt. or alternatively at least 25% of the mass. at 25 °C relative to its dry weight.

The contacting of the cross-linked substrate network with the graft composition is preferably carried out under such conditions that the graft composition penetrates the cross-linked substrate network and is more concentrated on the surface of the cross-linked substrate network than in the core. Various techniques can be used to provide a higher concentration of the graft composition at the surface than at the core. For example, as shown in the examples below, the cross-linked substrate network may be immersed in a liquid or solution containing the graft composition for a time sufficient to allow partial penetration of the graft composition into the substrate.

Alternatively, the cross-linked substrate network can be exposed to steam or supercritical fluid containing the grafting composition. The grafting composition may be a contact lens pack or storage solution, and the activation of the covalently bound, activated free radical polymerization initiator in the contact lens cross-linked substrate network may be carried out in the pack.

The cross-linked substrate network can be sequentially contacted with more than one grafting composition under the same or different curing conditions to form layers or regions with compositionally different or mixed grafted polymer networks.

Known analytical methods can be used to determine the relative concentration of the graft composition on the surface and in the core. Such analytical methods can be used either before or after curing of the graft composition. For example, an acceptable qualitative method suitable for use after curing is confocal microscopy, as shown in the examples.

After the cross-linked substrate network is brought into contact with the grafting composition, at least a portion of the activated free radical polymerization initiator in the cross-linked substrate network is activated. For example, if the polymerization initiator used in step (a) of the method is BAPO, then at least a portion of the free radical polymerization initiator covalently linked to the cross-linked substrate network (in this example, monoacylphosphine oxide) can be activated by irradiation at 420 nm or below. using an appropriate light source. Subsequently, the graft composition is polymerized and covalently grafted onto the cross-linked substrate network with a free radical polymerization initiator in the substrate. Thus, the product is an ophthalmic device made from a grafted polymer network. When the ophthalmic device is a soft hydrogel contact lens having, for example, a central portion thickness of 30 to 300 microns, it is preferred that the grafting composition (after curing) penetrate to a maximum depth of no more than 30% of the central portion thickness, preferably no more than 20% thickness of the central portion, more preferably not more than 10% of the thickness of the central portion, most preferably not more than 5% of the thickness of the central portion, or alternatively, the layer of cured graft composition may have a thickness in the central portion of the lens of not more than 90 microns, preferably from 9 to 90 microns, more preferably 6 to 60 microns and most preferably 3 to 30 microns as measured by confocal microscopy in accordance with the techniques described in the examples.

Additional optional grafting steps can be added. For example, after the grafting described above, the cross-linked substrate network can be contacted with a second grafting composition containing one or more ethylenically unsaturated compounds. Such a second composition may be grafted onto a substrate if the substrate contains residual covalently bound, activated free radical polymerization initiators.

It should be noted that the free radical polymerization initiator, covalently bound to the cross-linked substrate network, upon activation forms two groups of free radicals, one of which may not be covalently bound to the substrate. Therefore, some of the reactive components in the graft composition may polymerize via an unbound free radical group to form a polymer that is not covalently bound to the network. Such a polymer is referred to herein as a "side polymer". Covalent binding of this side polymer to the grafted polymer network can be induced by including a cross-linking agent in the graft composition. The composition may contain at least a portion of a by-product polymer that is not covalently bonded to the grafted polymer network. To achieve this goal, the polymerization of the graft composition is carried out essentially in the absence of a cross-linking agent. By "substantially no cross-linking agent" is meant that any cross-linking agent used in the graft composition is present in an amount less than a stoichiometric amount (i.e., less than the amount required to completely cross-link the by-polymer into the network) . In some embodiments, a cross-linking agent is not present in the graft composition.

The activation and polymerization of the graft composition and the cross-linked substrate network can, for example, be carried out by mixing the reactive components and the substrate in a vessel. A diluent may optionally be used to facilitate mixing and to facilitate swelling of the substrate (eg if it is not yet swollen or hydrated). The mixture may be degassed, heated, equilibrated, and irradiated under conditions that cause activation of the covalently bound, activated free radical initiator.

The first reactive composition and grafting composition(s) of the invention contain ethylenically unsaturated compounds as reactive components. The ethylenically unsaturated compounds undergo polymerization to form the polymer compositions described herein. It should be understood that a wide range of ethylenically unsaturated compounds can be used in the invention.

The ethylenically unsaturated compounds may be the same or different for the first reactive composition and the grafting composition, although in some embodiments it is preferred that at least some of the ethylenically unsaturated compounds in each composition be different. By using materials for the first reactive composition that are different from the grafting composition, it becomes possible to create ophthalmic devices that combine the desirable properties of materials that may not otherwise be readily compatible. This is one of the advantages of the invention.

The ethylenically unsaturated compound for inclusion in the first reactive and/or grafting composition may contain an independently selected silicone-containing component.

The silicone-containing component may contain one or more compounds selected from monomers or a macromer, where each compound may independently contain at least one polymerizable group, at least one siloxane group, and one or more linking groups connecting the polymerizable group(s)(- s) with siloxane(s) group(s). Silicone-containing components may, for example, contain from 1 to 220 siloxane repeating units, such as the groups described below. The silicone-containing component may also contain at least one fluorine atom.

The silicone-containing component may contain: one or more polymerizable groups as defined above; one or more optionally repeating siloxane units; and one or more linking groups linking the polymerizable groups to the siloxane units. The silicone-containing component may contain: one or more polymerizable groups, which are independently (meth)acrylate, styryl, vinyl ether, (meth)acrylamide, N-vinyl lactam, N-vinylamide, O-vinyl carbamate, O-vinyl carbonate, vinyl group, or mixtures of the above; one or more optionally repeating siloxane units; and one or more linking groups linking the polymerizable groups to the siloxane units.

The silicone-containing component may contain: one or more polymerizable groups which are independently (meth)acrylate, (meth)acrylamide, N-vinyl lactam, N-vinylamide, styryl, or mixtures of the foregoing; one or more optionally repeating siloxane units; and one or more linking groups linking the polymerizable groups to the siloxane units.

The silicone-containing component may contain: one or more polymerizable groups, which are independently (meth)acrylate, (meth)acrylamide, or mixtures of the foregoing; one or more optionally repeating siloxane units; and one or more linking groups linking the polymerizable groups to the siloxane units.

Formula A The silicone-containing component may contain one or more siloxane monomers or macromers of formula A:

,

,

Formula A

where:

at least one R ^A is a group of formula R _g -L-, where R _g is a polymerizable group and L is a linking group, and each of the remaining R ^A is independently:

(a) _Rg -L-,

(b) C ₁ -C ₁₆ alkyl optionally substituted with one or more of hydroxy, amino, amido, oxa, carboxy, alkylcarboxy, carbonyl, alkoxy, amido, carbamate, carbonate, halogen, phenyl, benzyl, or combinations thereof,

(c) C ₃ -C ₁₂ cycloalkyl optionally substituted with one or more of alkyl, hydroxy, amino, amido, oxa, carbonyl, alkoxy, amido, carbamate, carbonate, halogen, phenyl, benzyl, or combinations thereof,

(d) C ₆ -C ₁₄ aryl optionally substituted with one or more of alkyl, hydroxy, amino, amido, oxa, carboxy, alkylcarboxy, carbonyl, alkoxy, amido, carbamate, carbonate, halogen, phenyl, benzyl, or combinations thereof,

(e) halogen,

(f) alkoxy, cyclic alkoxy or aryloxy,

(g) siloxy,

(h) an alkyleneoxyalkyl or alkoxyalkyleneoxyalkyl such as polyethyleneoxyalkyl, polypropyleneoxyalkyl or poly(ethyleneoxysopropyleneoxyalkyl), or

(i) a monovalent siloxane chain containing from 1 to 100 siloxane repeating units optionally substituted with alkyl, alkoxy, hydroxy, amino, oxa, carboxy, alkylcarboxy, alkoxy, amido, carbamate, halogen, or combinations thereof; and

n is from 0 to 500, or from 0 to 200, or from 0 to 100, or from 0 to 20, and it is assumed that if n is different from 0, then n is a distribution having a mode equal to the declared value. If n is 2 or more, the SiO units may have the same or different R ^A substituents, and if different R ^A substituents are present, the n groups may have a random or block configuration.

In Formula ^A , each of the three RAs may contain a polymerizable group, alternatively, each of the two ^RAs may contain a polymerizable group, or alternatively, one ^RA may contain a polymerizable group.

Formula B The silicone-containing component of formula A may be a monofunctional compound of formula B:

,

,

Formula B

where:

Rg is a polymerizable group;

L is a linking group;

each of j1 and j2 is independently an integer from 0 to 220, provided that the sum of j1 and j2 is from 1 to 220;

R ^A1 , R ^A2 , R ^A3 , R ^A4 , R ^A5 and R ^A7 are each independently C ₁ -C ₆ alkyl, C ₃ -C ₁₂ cycloalkyl, C ₁ -C ₆ alkoxy, C ₄ -C ₁₂ cyclic alkoxy, alkoxyalkyleneoxyalkyl, aryl (e.g. phenyl), arylalkyl (e.g. benzyl), haloalkyl (e.g. partially or fully fluorinated alkyl), siloxy, fluoro, or combinations thereof, wherein each alkyl in the above groups is optionally substituted with one or more hydroxy, amino , amido, oxa, carboxy, alkylcarboxy, carbonyls, alkoxy, carbamates, carbonates, halogens, phenyls or benzyls, each cycloalkyl is optionally substituted with one or more alkyl, hydroxy, amino, amido, oxa, carbonyls, alkoxy, carbamates, carbonates, halogens, phenyls or benzyls, and each aryl is optionally substituted with one or more alkyl, hydroxy, amino, amido, oxa, carboxy, alkylcarboxy, carbonyls, alkoxy, carbamates, carbonates, halogens, phenyls, or benzyls; and

R ^A6 is siloxy, C ₁ -C ₈ alkyl (eg C ₁ -C ₄ alkyl or butyl or methyl) or aryl (eg phenyl), where alkyl and aryl may be optionally substituted with one or more fluorine atoms.

Formula B-1. Compounds of formula B may include compounds of formula B-1 which are compounds of formula B wherein j1 is zero and j2 is 1 to 220, or j2 is 1 to 100, or j2 is 1 to 50, or j2 is 1 to 20, or j2 is 1 to 5, or j2 is 1.

B-2. Compounds of formula B may include compounds of formula B-2 which are compounds of formula B wherein j1 and j2 are independently 4 to 100, or 4 to 20, or 4 to 10, or 24 to 100, or from 10 to 100.

B-3. The compounds of formulas B, B-1 and B-2 may include compounds of formula B-3, which are compounds of formula B, B-1 or B-2, where R ^A1 , R ^A2 , R ^A3 and R ^A4 independently in each case are C ₁ -C ₆ alkyl or siloxy. Preferred alkyl is C ₁ -C ₃ alkyl or more preferably methyl. A preferred siloxy group is a trimethylsiloxy group.

B-4. Compounds of formulas B, B-1, B-2 and B-3 may include compounds of formula B-4 which are compounds of formula B, B-1, B-2 or B-3, where R ^A5 and R ^A7 are independently are alkoxyalkyleneoxyalkyl, preferably independently are methoxy-closed polyethyleneoxyalkyl of the formula CH ₃ O-[CH ₂ CH ₂ O] _p -CH ₂ CH ₂ CH ₂ , where p is an integer from 1 to 50.

B-5. Compounds of formulas B, B-1, B-2 and B-3 may include compounds of formula B-5 which are compounds of formula B, B-1, B-2 or B-3, where R ^A5 and R ^A7 are independently are a siloxy group, for example a trimethylsiloxy group.

B-6. Compounds of formulas B, B-1, B-2 and B-3 may include compounds of formula B-6 which are compounds of formula B, B-1, B-2 or B-3, where R ^A5 and R ^A7 are independently are C ₁ -C ₆ alkyl, alternatively C ₁ -C ₄ alkyl or alternatively butyl or methyl.

B-7. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5 and B-6 may include compounds of formula B-7 which are compounds of formula B, B-1, B-2 , B-3, B-4, B-5 or B-6, where R ^A6 represents C ₁ -C ₈ alkyl, preferably C ₁ -C ₆ alkyl, more preferably C ₁ -C ₄ alkyl (for example, methyl, ethyl, n-propyl or n-butyl). More preferably R ^A6 is n-butyl.

B-8. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6 and B-7 may include compounds of formula B-8 which are compounds of formula B, B- 1, B-2, B-3, B-4, B-5, B-6 or B-7, where Rg contains styryl, vinyl carbonate, vinyl ether, vinyl carbamate, N-vinyl lactam, N-vinylamide, (meth) acrylate or (meth)acrylamide. Rg preferably contains (meth)acrylate, (meth)acrylamide or styryl. More preferably, Rg contains (meth)acrylate or (meth)acrylamide. If Rg is (meth)acrylamide, the nitrogen group may be substituted with R ^A9 , where R ^A9 is H, C ₁ -C ₈ alkyl (preferably C ₁ -C ₄ alkyl such as n-butyl, n-propyl, methyl or ethyl) or C ₃ -C ₈ cycloalkyl (preferably C ₅ -C ₆ cycloalkyl), wherein alkyl and cycloalkyl are optionally substituted with one or more groups independently selected from hydroxyl, amide, ether, silyl (e.g. trimethylsilyl), siloxy ( for example, trimethylsiloxy), alkylsiloxanyl (wherein the alkyl itself is optionally substituted with fluorine), arylsiloxanyl (wherein the aryl itself is optionally substituted with fluorine), and silyloxyalkylene (wherein the oxaalkylene itself is optionally substituted with hydroxyl).

B-9. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6, B-7 and B-8 may include compounds of formula B-9 which are compounds of formula B , B-1, B-2, B-3, B-4, B-5, B-6, B-7 or B-8, where the linking group contains alkylene (preferably C ₁ -C ₄ alkylene), cycloalkylene ( preferably C ₅ -C ₆ cycloalkylene), alkyleneoxy (preferably ethyleneoxy), haloalkyleneoxy (preferably haloethyleneoxy), amide, oxaalkylene (preferably having 3 to 6 carbon atoms), siloxanyl, alkylenesiloxanyl, carbamate, alkyleneamine (preferably C ₁ -C ₆ alkyleneamine ) or combinations of two or more of them, wherein the linking group is optionally substituted with one or more substituents independently selected from alkyl, hydroxyl, ether, amine, carbonyl, siloxy, and carbamate.

B-10. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 and B-9 may include compounds of formula B-10 representing are compounds of formula B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 or B-9, where the linking group is an alkylene-siloxanyl- alkylene-alkyleneoxy- or alkylene-siloxanyl-alkylene-[alkyleneoxy-alkylene-siloxanyl] _q -alkyleneoxy-, where q is from 1 to 50.

B-11. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 and B-9 may include compounds of formula B-11 representing are compounds of formula B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 or B-9, where the linking group is C_one-C₆ alkylene, preferably C_one-C₃ alkylene, more preferably n-propylene.

B-12. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 and B-9 may include compounds of formula B-12 representing are compounds of formula B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 or B-9, wherein the linking group is an alkylenecarbamatoxaalkylene. The linking group is preferably CH₂CH₂N(H)-C(=O)-O-CH₂CH₂-O-CH₂CH₂CH₂.

B-13. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 and B-9 may include compounds of formula B-13 representing are compounds of formula B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 or B-9, wherein the linking group is an oxaalkylene. The linking group is preferably CH₂CH₂-O-CH₂CH₂CH₂.

B-14. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 and B-9 may include compounds of formula B-14 which are are compounds of formula B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 or B-9, wherein the linking group is an alkylene-[siloxanyl -alkylene]_q- where q is from 1 to 50. An example of such a linking group: -(CH₂)₃-[Si(CH₃)₂-O-Si(CH₃)₂-(CH₂)₂]_q-.

B-15. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 and B-9 may include compounds of formula B-15 which are is a compound of formula B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 or B-9, where the linking group is an alkyleneoxycarbamatealkylenecycloalkylenecarbamoxaalkylene, and cycloalkylene optionally substituted with 1, 2 or 3 substituents independently selected from alkyl groups (preferably C_one-C₃ alkyl, more preferably methyl). An example of such a linking group is -[OCH₂CH₂]_q-OC(=O)-NH-CH₂-[1,3-cyclohexylene]-NHC(=O)O-CH₂CH₂-O-CH₂CH₂-, and cyclohexylene is substituted in positions 1 and 5 with three methyl groups.

B-16. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 and B-9 may include compounds of formula B-16 which are are compounds of formula B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 or B-9, where Rg contains styryl and the linking group is is an alkyleneoxy, wherein each alkylene in the alkyleneoxy is independently optionally substituted with hydroxyl. An example of such a linking group is -O-(CH₂)₃-. Another example of such a linking group is -O-CH₂CH(OH)CH₂-O-(CH₂)₃-.

B-17. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 and B-9 may include compounds of formula B-17 representing are compounds of formula B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 or B-9, where Rg contains styryl and the linking group is is an alkyleneamine. An example of such a linking group is -NH-(CH ₂ ) ₃ -.

B-18. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 and B-9 may include compounds of formula B-18 representing are compounds of formula B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 or B-9, where the linking group is an oxaalkylene, optionally substituted hydroxyl, siloxy or silylalkyleneoxy (the alkyleneoxy group itself being optionally substituted with hydroxyl). An example of such a linking group is -CH ₂ CH(G)CH ₂ -O-(CH ₂ ) ₃ - where G is hydroxyl. In another example, G is R ₃ SiO- where two R groups are trimethylsiloxy and the third is C ₁ -C ₈ alkyl (preferably C ₁ -C ₃ alkyl, more preferably methyl) or the third is C ₃ -C ₈ cycloalkyl. In yet another example, G is R ₃ Si-(CH ₂ ) ₃ -O-CH ₂ CH(OH)CH ₂ -O-, where two R groups are trimethylsiloxy and the third is C ₁ -C ₈ alkyl ( preferably C ₁ -C ₃ alkyl, more preferably methyl) or C ₃ -C ₈ cycloalkyl. In yet another example, G is a polymerizable group such as (meth)acrylate. Such compounds can act as cross-linking agents.

B-19. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 and B-9 may include compounds of formula B-19 representing are compounds of formula B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 or B-9, where Rg contains styryl and the linking group is is an aminoxaalkylene optionally substituted with hydroxyl. An example of such a linking group is -NH-CH₂CH(OH)CH₂-O-(CH₂)₃-.

B-20. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 and B-9 may include compounds of formula B-20 representing are compounds of formula B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 or B-9, where Rg contains styryl and the linking group is is an alkyleneoxycarbamatoxaalkylene. An example of such a linking group is -O-(CH ₂ ) ₂ -N(H)C(=O)O-(CH ₂ ) ₂ -O-(CH ₂ ) ₃ -.

B-21. Compounds of formulas B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 and B-9 may include compounds of formula B-21 representing are compounds of formula B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8 or B-9, wherein the linking group is an alkylenecarbamatoxaalkylene. An example of such a linking group is -(CH ₂ ) ₂ -N(H)C(=O)O-(CH ₂ ) ₂ -O-(CH ₂ ) ₃ -.

Formula C. Silicone-containing components of formulas A, B, B-1, B-2, B-3, B-4, B-5, B-6, B-7, B-8, B-9, B-10, B-11, B-12, B-13, B-14, B-15, B-18 and B-21 may include compounds of formula C which are compounds of formula A, B, B-1, B-2 , B-3, B-4, B-5, B-6, B-7, B-8, B-9, B-10, B-11, B-12, B-13, B-14, B -15, B-18 or B-21 having the structure:

,

,

Formula C

where:

R ^A8 is hydrogen or methyl;

Z is O, S or N(R ^A9 ); and

L, j1, j2, R ^A1 , R ^A2 , R ^A3 , R ^A4 , R ^A5 , R ^A6 , R ^A7 and R ^A9 are defined as specified in formula B or its various subformulas (for example, B-1, B-2 , etc.).

C-1. Compounds of Formula C may include (meth)acrylates of Formula C-1 which are compounds of Formula C wherein Z is O.

C-2. Compounds of formula C may include (meth)acrylamides of formula C-2 which are compounds of formula C wherein Z is N(R ^A9 ) and R ^A9 is H.

C-3. Compounds of formula C may include (meth)acrylamides of formula C-3 which are compounds of formula C wherein Z is N(R ^A9 ) and R ^A9 is C ₁ -C ₈ alkyl, unsubstituted or optionally substituted as indicated above. Examples of R ^A9 include CH ₃ , -CH ₂ CH(OH)CH ₂ (OH), -(CH ₂ ) ₃ -siloxanyl, -(CH ₂ ) ₃ -SiR ₃ and -CH ₂ CH(OH)CH ₂ -O-(CH ₂ ) ₃ -SiR ₃ where each R in the above groups is independently selected from trimethylsiloxy, C ₁ -C ₈ alkyl (preferably C ₁ -C ₃ alkyl, more preferably methyl) and C ₃ -C ₈ cycloalkyl. Additional examples of R ^A9 include: -(CH ₂ ) ₃ -Si(Me)(SiMe ₃ ) ₂ and -(CH ₂ ) ₃ -Si(Me ₂ )-[O-SiMe ₂ ] _1-10 -CH ₃ .

Formula D Compounds of formula C may include compounds of formula D:

,

,

Formula D

where:

R ^A8 is hydrogen or methyl;

Z ¹ represents O and N(R ^A9 );

L ¹ is an alkylene containing from 1 to 8 carbon atoms, or an oxaalkylene containing from 3 to 10 carbon atoms, where L ¹ is optionally substituted with hydroxyl; and

j2, R ^A3 , R ^A4 , R ^A5 , R ^A6 , R ^A7 and R ^A9 are defined as defined above in formula B or its various subformulas (eg, B-1, B-2, etc.).

D-1. Compounds of formula D may include compounds of formula D-1 which are compounds of formula D wherein L ¹ is C ₂ -C ₅ alkylene optionally substituted with hydroxyl. Preferably L ¹ is n-propylene optionally substituted with hydroxyl.

D-2. The compounds of formula D may include compounds of formula D-2, which are compounds of formula D, where L ¹ represents oxaalkylene containing 4-8 carbon atoms, optionally substituted with hydroxyl. L ¹ is preferably an oxaalkylene containing five or six carbon atoms optionally substituted with hydroxyl. Examples include -(CH ₂ ) ₂ -O-(CH ₂ ) ₃ - and -CH ₂ CH(OH)CH ₂ -O-(CH ₂ ) ₃ -.

D-3. Compounds of formulas D, D-1 and D-2 may include compounds of formula D-3 which are compounds of formula D, D-1 or D-2 where Z ¹ is O.

D-4. Compounds of formulas D, D-1 and D-2 may include compounds of formula D-4 which are compounds of formula D, D-1 or D-2, where Z ¹ is N(R ^A9 ) and R ^A9 is H.

D-5. Compounds of formulas D, D-1 and D-2 may include compounds of formula D-5 which are compounds of formula D, D-1 or D-2, where Z ¹ is N(R ^A9 ) and R ^A9 is C ₁ -C ₄ alkyl optionally substituted with 1 or 2 substituents selected from hydroxyl, siloxy and C ₁ -C ₆ alkylsiloxanyl.

D-6. Compounds of formulas D, D-1, D-2, D-3, D-4 and D-5 may include compounds of formula D-6 which are compounds of formula D, D-1, D-2, D-3 , D-4 or D-5 where j2 is 1.

D-7. Compounds of formulas D, D-1, D-2, D-3, D-4 and D-5 may include compounds of formula D-7 which are compounds of formula D, D-1, D-2, D-3 , D-4 or D-5, where j2 is 2 to 220, or 2 to 100, or 10 to 100, or 24 to 100, or 4 to 20, or 4 to 10.

D-8. Compounds of formulas D, D-1, D-2, D-3, D-4, D-5, D-6 and D-7 may include compounds of formula D-8 which are compounds of formula D, D-1 , D-2, D-3, D-4, D-5, D-6 or D-7, where R ^A3 , R ^A4 , R ^A5 , R ^A6 and R ^A7 independently represent C ₁ -C ₆ alkyl or siloxy. Preferably R ^A3 , R ^A4 , R ^A5 , R ^A6 and R ^A7 are independently selected from methyl, ethyl, n-propyl, n-butyl and trimethylsiloxy. More preferably R ^A3 , R ^A4 , R ^A5 , R ^A6 and R ^A7 are independently selected from methyl, n-butyl and trimethylsiloxy.

D-9. Compounds of formulas D, D-1, D-2, D-3, D-4, D-5, D-6 and D-7 may include compounds of formula D-9 which are compounds of formula D, D- 1, D-2, D-3, D-4, D-5, D-6, or D-7, where R ^A3 and R ^A4 are independently C ₁ -C ₆ alkyl (eg methyl or ethyl) or siloxy (eg trimethylsiloxy) and R ^A5 , R ^A6 and R ^A7 are independently C ₁ -C ₆ alkyl (eg methyl, ethyl, n-propyl or n-butyl).

Formula E A silicone-containing component for use in the invention may comprise a multi-functional silicone-containing component. Thus, for example, a silicone-containing component of formula A may contain a bifunctional material of formula E:

,

,

Formula E

where:

Rg, L, j1, j2, R ^A1 , R ^A2 , R ^A3 , R ^A4 , R ^A5 and R ^A7 are defined as above in formula B or its various subformulas (e.g., B-1, B-2, etc. . P.);

L ² is a linking group; and

Rg ¹ is a polymerizable group.

E-1. Compounds of formula E may include compounds of formula E-1 which are compounds of formula E, wherein Rg and Rg ¹ are each a vinyl carbonate of structure CH ₂₌ CH-OC(=O)-O- or structure CH ₂₌ C( CH ₃ )-OC(=O)-O-.

E-2. The compounds of formula E may include compounds of formula E-2, which are compounds of formula E, where each of Rg and Rg ¹ represents (meth)acrylate.

E-3. Compounds of formula E may include compounds of formula E-3, which are compounds of formula E, where each of Rg and Rg ¹ represents (meth)acrylamide, and the nitrogen group may be substituted by R ^A9 (with R ^A9 defined as above ).

E-4. Suitable compounds of formulas E, E-1, E-2 and E-3 include compounds of formula E-4 which are compounds of formula E, E-1, E-2 or E-3, where j1 is zero and j2 is 1 to 220, or j2 is 1 to 100, or j2 is 1 to 50, or j2 is 1 to 20.

E-5. Suitable compounds of formulas E, E-1, E-2 and E-3 include compounds of formula E-5 which are compounds of formula E, E-1, E-2 or E-3, where j1 and j2 are independently from 4 to 100.

E-6. Suitable compounds of formulas E, E-1, E-2, E-3, E-4 and E-5 include compounds of formula E-6 which are compounds of formula E, E-1, E-2, E-3 , E-4 or E-5, where R ^A1 , R ^A2 , R ^A3 , R ^A4 and R ^A5 independently each represent C ₁ -C ₆ alkyl, preferably independently represent C ₁ -C ₃ alkyl or each preferably is methyl.

E-7. Suitable compounds of formulas E, E-1, E-2, E-3, E-4, E-5 and E-6 include compounds of formula E-7 which are compounds of formula E, E-1, E-2 , E-3, E-4, E-5 or E-6, where R ^A7 is an alkoxyalkyleneoxyalkyl, preferably a methoxy closed polyethyleneoxyalkyl of the formula CH ₃ O-[CH ₂ CH ₂ O] _p -CH ₂ CH ₂ CH ₂ where p is an integer from 1 to 50, or from 1 to 30, or from 1 to 10, or from 6 to 10.

E-8. Suitable compounds of formulas E, E-1, E-2, E-3, E-4, E-5, E-6 and E-7 include compounds of formula E-8 which are compounds of formula E, E-1 , E-2, E-3, E-4, E-5, E-6 or E-7, where L contains alkylene, carbamate, siloxanyl, cycloalkylene, amide, haloalkyleneoxy, oxaalkylene, or combinations of two or more of them, and the linking group is optionally substituted with one or more substituents independently selected from alkyl, hydroxyl, ether, amine, carbonyl, and carbamate.

E-9. Suitable compounds of formulas E, E-1, E-2, E-3, E-4, E-5, E-6, E-7 and E-8 include compounds of formula E-9 which are compounds of formula E , E-1, E-2, E-3, E-4, E-5, E-6, E-7 or E-8, where L ² contains alkylene, carbamate, siloxanyl, cycloalkylene, amide, haloalkyleneoxy, oxaalkylene or combinations of two or more of them, wherein the linking group is optionally substituted with one or more substituents independently selected from alkyl, hydroxyl, ether, amine, carbonyl, and carbamate. Examples of silicone-containing components suitable for use in the invention include, without limitation, the compounds listed in Table 1. If the compounds in Table 1 contain polysiloxane groups, then the number of SiO repeating units in such compounds, unless otherwise indicated, is preferably from 3 to 100, more preferably 3 to 40, or even more preferably 3 to 20.

Table 1

one monomethacryloxypropyl and mono-n-butyl terminated polydimethylsiloxanes (mPDMS) (preferably containing 3 to 15 SiO repeating units) 2 polydimethylsiloxane with monoacryloxypropyl and mono-n-butyl end groups 3 polydimethylsiloxane with mono(meth)acryloxypropyl and mono-n-methyl end groups four polydiethylsiloxane with mono(meth)acryloxypropyl and mono-n-butyl end groups 5 polydiethylsiloxane with mono(meth)acryloxypropyl and mono-n-methyl end groups 6 mono(meth)acrylamidoalkylpolydialkylsiloxanes 7 monoalkylpolydiarylsiloxanes with mono(meth)acryloxyalkyl end groups eight 3-methacryloxypropyltris(trimethylsiloxy)silane (TRIS) 9 3-Methacryloxypropylbis(trimethylsiloxy)methylsilane ten 3-methacryloxypropylpentamethyldisiloxane eleven mono(meth)acrylamidoalkylpolydialkylsiloxanes 12 mono(meth)acrylamidoalkylpolydimethylsiloxanes 13 N-(2,3-dihydroxypropane)-N'-(propyltetra(dimethylsiloxy)dimethylbutylsilane)acrylamide fourteen 3-acrylamidopropyl-tri(trimethylsiloxy)silane (TRIS-Am) fifteen 2-hydroxy-3-[3-methyl-3,3-di(trimethylsiloxy)silylpropoxy]propyl methacrylate (SiMAA) 16 2-hydroxy-3-methacryloxypropyloxypropyltris(trimethylsiloxy)silane 17 mono(2-hydroxy-3-methacryloxypropyl)propylether and mono-n-butyl terminated polydimethylsiloxanes (OH-mPDMS) (containing 4 to 30, or 10 to 20, or 4 to 8 SiO repeating units) eighteen

19

twenty

21

22

23

24

Additional non-limiting examples of suitable silicone-containing components are listed in Table 2. Unless otherwise indicated, where applicable, j2 is preferably 1 to 100, more preferably 3 to 40, or even more preferably 3 to 15. In compounds containing j1 and j2, the sum of j1 and j2 is preferably 2 to 100, more preferably 3 to 40, or even more preferably 3 to 15.

table 2

25

26

p is between 1 and 10 27

p is between 5 and 10 28

29

thirty 1,3-bis[4-(vinyloxycarbonyloxy)but-1-yl]tetramethyldisiloxane 31 3-(vinyloxycarbonylthio)propyl[tris(trimethylsiloxy)silane] 32 3-[tris(trimethylsiloxy)silyl]propylallyl carbamate 33 3-[tris(trimethylsiloxy)silyl]propylvinylcarbamate 34 tris(trimethylsiloxy)silylstyrene (Styryl-TRIS) 35

36

37

38

39

40

41

The ethylenically unsaturated compound to be included in the first reactive and/or grafting composition may contain an independently selected hydrophilic component. Hydrophilic components include those capable of providing at least about 20% or at least about 25% of the water content of the resulting composition in combination with the remaining reactive components. Suitable hydrophilic components include hydrophilic monomers, prepolymers and polymers. The hydrophilic component preferably has at least one polymerizable group and at least one hydrophilic functional group. Examples of polymerizable groups include acrylic, methacrylic, acrylamide, methacrylamide, fumaric, maleic, styryl, isopropenylphenyl, O-vinyl carbonate, O-vinylcarbamate, allyl, O-vinylacetyl, and N -vinyl lactam and N -vinylamide double bonds.

The terms "vinyl type" or "vinyl-containing" monomers refer to monomers containing a vinyl group (-CH=CH ₂ ) and being essentially highly reactive. It is known that such hydrophilic vinyl-containing monomers are relatively easy to polymerize.

"Acrylic-type" or "acrylic-containing" monomers are monomers containing an acrylic group (CH ₂ =CRCOX) where R is H or CH ₃ and X is O or N, which are also known for their ease of polymerization, such as N , N -dimethylacrylamide (DMA), 2-hydroxyethyl methacrylamide, polyethylene glycol monomethacrylate, methacrylic acid, acrylic acid, mixtures thereof, etc.

You can use hydrophilic monomers with at least one hydroxyl group (hydroxyalkyl monomer). Such a hydroxyalkyl group may be selected from C ₂ -C ₄ mono- or dihydroxy-substituted alkyl and poly(ethylene glycol) having 1-10 repeating units; or may be selected from 2-hydroxyethyl, 2,3-dihydroxypropyl or 2-hydroxypropyl and combinations thereof.

Examples of hydroxyalkyl monomers include 2-hydroxyethyl(meth)acrylate, 3-hydroxypropyl(meth)acrylate, 2-hydroxypropyl(meth)acrylate, 2,3-dihydroxypropyl(meth)acrylate, 2-hydroxybutyl(meth)acrylate, 3- hydroxybutyl(meth)acrylate, 1-hydroxypropyl-2-(meth)acrylate, 2-hydroxy-2-methylpropyl(meth)acrylate, 3-hydroxy-2,2-dimethylpropyl(meth)acrylate, 4-hydroxybutyl(meth)acrylate , 2-hydroxyethyl(meth)acrylamide, N- (2-hydroxypropyl)(meth)acrylamide, N,N-bis(2-hydroxyethyl)(meth)acrylamide, N,N-bis(2-hydroxypropyl)(meth)acrylamide , N-(3-hydroxypropyl)(meth)acrylamide, 2,3-dihydroxypropyl(meth)acrylamide, glycerol(meth)acrylate, polyethylene glycol monomethacrylate and mixtures thereof.

The hydroxyalkyl monomer may also be selected from the group consisting of 2-hydroxyethyl methacrylate, glycerol methacrylate, 2-hydroxypropyl methacrylate, hydroxybutyl methacrylate, 3-hydroxy-2,2-dimethylpropyl methacrylate, and mixtures thereof.

The hydroxyalkyl monomer may contain 2-hydroxyethyl methacrylate, 3-hydroxy-2,2-dimethylpropyl methacrylate, hydroxybutyl methacrylate, or glycerol methacrylate.

If hydrophilic polymers are required in amounts greater than about 3 wt %, the hydroxyl-containing (meth)acrylamides are essentially too hydrophilic to be incorporated as hydroxyalkyl monomer compatibilizers. Therefore, hydroxyl-containing (meth)acrylates can be added to the reactive composition to obtain a haze index in the final lens of less than about 50% or less than about 30%, and a lower amount of hydroxyalkyl monomers can be selected.

It should be understood that the amount of the hydroxyl component will vary depending on several factors, including the number of hydroxyl groups in the hydroxyalkyl monomer, weight, molecular weight, and the presence of a hydrophilic functional group in the silicone-containing components. The hydrophilic hydroxyl component may be present in the reactive composition in amounts of no more than about 15%, no more than about 10% wt., from about 3 to about 15% wt. or about 5 and about 15% of the mass.

Hydrophilic vinyl-containing monomers that can be incorporated into polymer compositions include monomers such as hydrophilic N-vinyl lactam and N-vinylamide monomers including: N-vinylpyrrolidone (NVP), N-vinyl-2-piperidone, N-vinyl-2 -caprolactam, N-vinyl-3-methyl-2-caprolactam, N-vinyl-3-methyl-2-piperidone, N-vinyl-4-methyl-2-piperidone, N-vinyl-4-methyl-2-caprolactam , N-vinyl-3-ethyl-2-pyrrolidone, N-vinyl-4,5-dimethyl-2-pyrrolidone, N-vinylacetamide (NVA), N-vinyl-N-methylacetamide (VMA), N-vinyl-N -ethylacetamide, N-vinyl-N-ethylformamide, N-vinylformamide, N-vinyl-N-methylpropionamide, N-vinyl-N-methyl-2-methylpropionamide, N-vinyl-2-methylpropionamide, N-vinyl-N, N '-dimethylurea, 1-methyl-3-methylene-2-pyrrolidone, 1-methyl-5-methylene-2-pyrrolidone, 5-methyl-3-methylene-2-pyrrolidone; 1-ethyl-5-methylene-2-pyrrolidone, N-methyl-3-methylene-2-pyrrolidone, 5-ethyl-3-methylene-2-pyrrolidone, 1-N-propyl-3-methylene-2-pyrrolidone, 1-N-propyl-5-methylene-2-pyrrolidone, 1-isopropyl-3-methylene-2-pyrrolidone, 1-isopropyl-5-methylene-2-pyrrolidone, N-vinyl-N-ethylacetamide, N-vinyl- N-ethylformamide, N-vinylformamide, N-vinylisopropylamide, N-vinylcaprolactam, N-carboxyvinyl-β-alanine (VINAL), N-carboxyvinyl-α-alanine, N-vinylimidazole and mixtures thereof.

Hydrophilic O-vinyl carbamate and O-vinyl carbonate monomers that can be used in the invention include: N-2-hydroxyethyl vinyl carbamate and N-carboxy-ß-alanine N-vinyl ester. Additional examples of hydrophilic vinyl carbonate or vinyl carbamate monomers are described in US Pat. No. 5,070,215 and hydrophilic oxazolone monomers are described in US Pat. No. 4,910,277.

Examples of useful vinyl carbamates and carbonates include: N -2-hydroxyethyl vinyl carbamate, N -carboxy-β-alanine, N -vinyl ether, other hydrophilic vinyl monomers including vinyl imidazole, ethylene glycol vinyl ether (EGVE), di vinyl ether (ethylene glycol) (DEGVE), allyl alcohol, 2-ethyloxazoline, vinyl acetate, acrylonitrile and mixtures thereof.

(Meth)acrylamide monomers can also be used as hydrophilic monomers. Examples include N,N -dimethylacrylamide, acrylamide, N,N -bis(2-hydroxyethyl)acrylamide, acrylonitrile, N -isopropylacrylamide, N,N -dimethylaminopropyl(meth)acrylamide, and any of the above hydroxyl-functionalized (meth)acrylamides .

Hydrophilic monomers that can be incorporated into the polymers described herein can be selected from N,N -dimethylacrylamide (DMA), 2-hydroxyethylacrylamide, 2-hydroxyethylmethacrylamide, N -hydroxypropylmethacrylamide, bishydroxyethylacrylamide, 2,3-dihydroxypropyl(meth) acrylamide, N -vinylpyrrolidone (NVP), N -vinyl- N -methylacetamide, N -vinylmethacetamide (VMA), and polyethylene glycol monomethacrylate.

The hydrophilic monomers may be selected from DMA, NVP, VMA, NVA and mixtures thereof.

The hydrophilic monomers can be macromers of linear or branched poly(ethylene glycol), poly(propylene glycol), or random or block copolymers of ethylene oxide and propylene oxide. The macromer of such polyethers has one polymerizable group. Non-limiting examples of such polymerizable groups are acrylates, methacrylates, styrenes, vinyl ethers, acrylamides, methacrylamides and other vinyl compounds. The macromer of such polyethers may contain acrylates, methacrylates, acrylamides, methacrylamides and mixtures thereof. Other suitable hydrophilic monomers will be apparent to those skilled in the art.

Hydrophilic monomers may also contain charged monomers including, but not limited to, acrylic acid, methacrylic acid, 3-acrylamidopropionic acid (ACA1), 4-acrylamidobutanoic acid, 5-acrylamidopentanoic acid (ACA2), 3-acrylamido-3-methylbutanoic acid (AMBA ), N-vinyloxycarbonyl-α-alanine, N-vinyloxycarbonyl-β-alanine (VINAL), 2-vinyl-4,4-dimethyl-2-oxazolin-5-one (VDMO), reactive sulfonic acid salts including sodium 2-(acrylamido)-2-methylpropanesulfonate (AMPS), 3-sulfopropyl(meth)acrylate potassium salt, 3-sulfopropyl(meth)acrylate sodium salt, disodium bis-3-sulfopropylitaconate, dipotassium bis-3-sulfopropylitaconate, vinylsulfonic sodium salt acids, vinyl sulfonic acid salt, styrene sulfonate, sulfoethyl methacrylate, combinations thereof, and the like.

Hydrophilic monomers can be selected from N,N-dimethylacrylamide (DMA), N-vinyl pyrrolidone (NVP), 2-hydroxyethyl methacrylate (HEMA), N-vinyl methacetamide (VMA) and N-vinyl-N-methylacetamide (NVA), N -hydroxypropyl methacrylamide , monoglycerol methacrylate, 2-hydroxyethyl acrylamide, 2-hydroxyethyl methacrylamide, bishydroxyethyl acrylamide, 2,3-dihydroxypropyl(meth)acrylamide, and mixtures thereof.

The hydrophilic monomers may be selected from DMA, NVP, HEMA, VMA, NVA and mixtures thereof.

The hydrophilic monomer(s) (including hydroxyalkyl monomers) may be present in the composition in amounts of not more than about 60% by weight, from about 1 to about 60% by weight, from about 5 to about 50% by weight. . or from about 5 to about 40% of the mass. based on the weight of all reactive components.

Other hydrophilic monomers that can be used include polyoxyethylene polyols having one or more terminal hydroxyl groups replaced by a polymerizable group. Examples include polyethylene glycol in which one or more terminal hydroxyl groups have been replaced with a polymerizable group. Examples include polyethylene glycol reacted with one or more molar equivalents of a closing group such as isocyanatoethyl methacrylate (IEM), methacrylic anhydride, methacryloyl chloride, vinyl benzoyl chloride, or the like to form a polyethylene polyol having one or more terminal polymerizable olefinic groups, linked to the polyethylene polyol via linking functional groups such as carbamate or ester groups.

Additional examples are the hydrophilic vinyl carbonate or vinyl carbamate monomers described in US Pat. No. 5,070,215 and the hydrophilic oxazolone monomers described in US Pat. No. 4,190,277. Other suitable hydrophilic monomers will be apparent to those skilled in the art.

Hydrophilic monomers that may be included in the polymer compositions described herein include hydrophilic monomers such as N,N -dimethylacrylamide (DMA), 2-hydroxyethyl acrylate, glycerol methacrylate, 2-hydroxyethylmethacrylamide, N -vinylpyrrolidone (NVP), N -vinylmethacrylamide, HEMA and poly(ethylene glycol) methyl ether methacrylate (mPEG).

Hydrophilic monomers may include DMA, NVP, HEMA, and mixtures thereof.

The first reactive composition and/or grafting composition may contain one or more independently selected zwitterionic ethylenically unsaturated compounds, such as ethylenically unsaturated betaine. Preferably the zwitterionic compound is in the graft composition. Examples of suitable compounds include: N-(2-carboxyethyl)-N, N-dimethyl-3-[(1-oxo-2-propen-1-yl)amino]-1-propanaminium internal salt (CAS 79704-35 -1, also known as 3-acrylamido-N-(2-carboxyethyl)-N, N-dimethylpropane-1-aminium or CBT); 3-methacrylamido-N-(2-carboxyethyl)-N,N-dimethylpropane-1-aminium; N,N-dimethyl-N-[3-[(1-oxo-2-propen-1-yl)amino]propyl]-3-sulfo-1-propanaminium internal salt (CAS 80293-60-3, also known as 3-((3-acrylamidopropyl)dimethylammonio)propane-1-sulfonate or SBT); 3-((3-methacrylamidopropyl)dimethylammonio)propane-1-sulfonate; 3,5-dioxa-8-aza-4-phosphoundec-10-en-1-aminium, 4-hydroxy-N, N,N-trimethyl-9-oxo internal salt, 4-oxide (CAS 163674-35-9 , PBT); 2-(acrylamidoethoxy)-(2-(trimethylammonio)ethyl)phosphate; 2-(methacrylamidoethoxy)-(2-(trimethylammonio)ethyl)phosphate; 4-hydroxy-N, N,N, 10-tetramethyl-9-oxo-3,5,8-trioxa-4-phosphonoundec-10-en-1-aminium internal salt, 4-oxide (CAS 67881-98-5 also known as 2-(methacryloyloxy)ethyl-(2-(trimethylammonio)ethyl)phosphate or MPC); or 2-(acryloyloxy)ethyl-(2-(trimethylammonio)ethyl)phosphate.

The first reactive composition and/or grafting composition may contain one or more independently selected ethylenically unsaturated quaternary ammonium salts. Preferably the quaternary ammonium salt is in the graft composition. Examples of suitable compounds include 2-(methacryloyloxy)ethyltrimethylammonium chloride; 2-(acryloyloxy)ethyltrimethylammonium chloride; 3-methacrylamido-N,N,N-trimethylpropane-1-aminium chloride; or 3-acrylamido-N,N,N-trimethylpropane-1-aminium chloride.

The first reactive composition and/or grafting composition may contain one or more independently selected ethylenically unsaturated active pharmaceutical ingredients. Preferably the active pharmaceutical compound is in the grafting composition. Examples of suitable compounds include cyclosporine or salicylate monomers.

The first reactive composition and/or grafting composition may contain one or more independently selected ethylenically unsaturated peptides. Preferably the peptide is in the graft composition. Exemplary compounds include, for example, those in which the amino terminus of the peptide can be acylated with an acylating agent such as (meth)acryloyl chloride, (meth)acrylic anhydride, isopropenyl-α,α-dimethylbenzyl isocyanate, and 2-isocyanatoethyl methacrylate, in combination with known co-reagents and catalysts to form a monomer suitable for inclusion in the reactive compositions of the present invention.

The first reactive composition of the invention contains a cross-linking agent. Cross-linking agents may optionally be present in the graft composition. You can use a variety of crosslinkers, including containing and not containing silicone crosslinkers and mixtures thereof. Examples of suitable crosslinkers include ethylene glycol dimethacrylate (EGDMA), diethylene glycol dimethacrylate, trimethylol propane trimethacrylate (TMPTMA), tetraethylene glycol dimethacrylate (TEGDMA), triallyl cyanurate (TAC), glycerol trimethacrylate, 1,3-propanediol dimethacrylate; 2,3-propanediol dimethacrylate; 1,6-hexanediol dimethacrylate; 1,4-butanediol dimethacrylate, methacryloxyethyl vinyl carbonate (HEMAVc), allyl methacrylate, methylene bisacrylamide (MBA), polyethylene glycol dimethacrylate (the polyethylene glycol preferably having a molecular weight of not more than 5000 daltons). Crosslinkers are used in typical amounts known to those skilled in the art, for example, from about 0.000415 to about 0.0156 moles per 100 g of reactive components in the reactive composition.

If an ethylenically unsaturated compound, such as a hydrophilic monomer or a silicone-containing monomer, acts as a crosslinker, for example due to its bifunctionality or multifunctionality, the addition of a separate crosslinker to the reactive composition is optional. In this case, the ethylenically unsaturated compound is also considered a cross-linking agent. Examples of hydrophilic monomers that can act as crosslinkers and which do not require the addition of additional crosslinkers to the reactive composition include the polyoxyethylene polyols described above and containing two or more terminal methacrylate functional groups. An example of a silicone-containing monomer that can act as a cross-linking agent and which does not require the addition of additional cross-linking agents to the reactive composition includes α, ω-bismethacrylo-propylpolydimethylsiloxane. In addition, any of the multifunctional silicone-containing components described above can be used as cross-linking agents.

Any or both of the first reactive composition and the grafting composition may contain additional components such as, but not limited to, UV absorbers, photochromic compounds, pharmaceutical and nutraceutical compounds, antimicrobial compounds, reactive coloring agents, pigments, copolymerizable and non-polymerizable dyes, release agents. and their combinations. Other components that may be present in the first reactive and/or graft composition include wetting agents such as those described in US 6,367,929, WO03/22321, WO03/22322, compatibilizers such as those described in US2003/162862 and US2003/125498. In the amount of additional components can be no more than about 20% of the mass. Reactive compositions may contain no more than about 18% of the mass. wetting agent or from about 5 to about 18% of the mass. wetting agent.

As used herein, the term "wetting agent" is a hydrophilic polymer having a weight average molecular weight greater than about 5,000 daltons, from about 150,000 daltons to about 2,000,000 daltons; from about 300,000 daltons to about 1,800,000 daltons; or from about 500,000 daltons to about 1,500,000 daltons.

The amount of optional wetting agent that may be added to the first reactive composition and/or grafting composition of the present invention may vary depending on the other components used and the desired properties of the resulting product. When present in the reactive compositions, internal wetting agents may be included in amounts from about 1% wt. up to about 20% wt.; from about 2% of the mass. up to about 15 percent or from about 2% of the mass. up to about 12 percent based on the total weight of all reactive components. Preferably, the wetting agent, if used, is present in the first reactive composition.

Wetting agents include, without limitation, homopolymers, random copolymers, diblock copolymers, triblock copolymers, segmented block copolymers, graft copolymers, and mixtures thereof. Non-limiting examples of internal wetting agents are polyamides, polyesters, polylactones, polyimides, polylactams, polyethers, polyacids in the form of homopolymers and copolymers obtained by free radical polymerization of appropriate monomers, including acrylates, methacrylates, styrenes, vinyl ethers, acrylamides, methacrylamides. , N-vinyl lactams, N-vinylamides, O-vinyl carbamates, O-vinyl carbonates and other vinyl compounds. Wetting agents can be derived from any hydrophilic monomers, including those listed herein.

Wetting agents may include acyclic polyamides which contain pendent acyclic amide groups and are capable of associating with hydroxyl groups. Cyclic polyamides contain cyclic amide groups and are also capable of associating with hydroxyl groups.

Examples of suitable acyclic polyamides include polymers and copolymers containing repeat units of Formula XXIX or Formula XXX:

where X is a direct bond, -(CO)- or -(CO)-NHR ^e -, where R ²⁶ and R ²⁷ represent H or methyl groups; where R ^e represents a C ₁ -C ₃ alkyl group; R ^a is selected from H, linear or branched, substituted or unsubstituted C ₁ -C ₄ alkyl groups; R ^b is selected from H, linear or branched, substituted or unsubstituted C ₁ -C ₄ alkyl groups, amino groups having up to two carbon atoms, amide groups having up to four carbon atoms, and alkoxy groups having up to two carbon groups; R ^c is selected from H, linear or branched, substituted or unsubstituted C ₁ -C ₄ alkyl groups or from methyl, ethoxy, hydroxyethyl and hydroxymethyl; R ^d is selected from H, linear or branched, substituted or unsubstituted C ₁ -C ₄ alkyl groups; or from methyl, ethoxy, hydroxyethyl and hydroxymethyl, and the total number of carbon atoms in R ^a and R ^b is 8 or less, including 7, 6, 5, 4, 3 or less, and while the total number of carbon atoms in R ^c and R ^d is 8 or less, including 7, 6, 5, 4, 3 or less. The total number of carbon atoms in R ^a and R ^b may be 6 or less or 4 or less. The total number of carbon atoms in R ^c and R ^d may be 6 or less. As used herein, the term "substituted alkyl groups" includes alkyl groups substituted with amino, amide, ether, hydroxyl, carbonyl, carboxyl groups, or combinations thereof.

R ^a and R ^b may be independently selected from H, substituted or unsubstituted C ₁ -C ₂ alkyl groups. X may be a direct bond, and R ^a and R ^b may be independently selected from H, substituted or unsubstituted C ₁ -C ₂ alkyl groups.

R ^c and R ^d may be independently selected from H, substituted or unsubstituted C ₁ -C ₂ alkyl groups, methyl, ethoxy, hydroxyethyl and hydroxymethyl.

The acyclic polyamides of the present invention may contain most of the repeating units of Formula XXIX or Formula XXX, or the acyclic polyamides may contain at least about 50 mole % of repeating units of Formula XXIX or Formula XXX, including at least about 70 mole % and at least about 80 mole %.

Specific examples of repeating units of formulas XXIX and XXX include repeating units derived from N -vinyl- N -methacetamide, N -vinylacetamide, N -vinyl- N -methylpropionamide, N -vinyl- N -methyl-2-methylpropionamide, N- vinyl-2-methylpropionamide, N -vinyl- N, N' -dimethylurea, N, N -dimethylacrylamide, methacrylamide and acyclic amides of formulas XXXI and XXXII:

Examples of suitable cyclic amides that can be used to form cyclic polyamides include α-lactam, β-lactam, γ-lactam, δ-lactam and ε-lactam. Examples of suitable cyclic polyamides include polymers and copolymers containing repeating units of formula XXXIII:

where f is a number from 1 to 10, X is a direct bond, -(CO)- or -(CO)-NH-R ^e -, where R ^e represents a C ₁ -C ₃ alkyl group and R ²⁸ represents a hydrogen atom or a methyl group. In formula XXXIII, f may be 8 or less, including 7, 6, 5, 4, 3, 2, or 1. In formula XXXIII, f may be 6 or less, including 5, 4, 3, 2, or 1, or may be from 2 to 8, including 2, 3, 4, 5, 6, 7 or 8, or may be 2 or 3.

If X is a direct bond, f may be 2. In such cases, the cyclic polyamide may be polyvinylpyrrolidone (PVP).

Cyclic polyamides may contain 50 mole % or more of Formula XXXIII repeating units, or cyclic polyamides may contain at least about 50 mole % of Formula XXXIII repeating units, including at least about 70 mole % and at least about 80 mole %.

Specific examples of repeat units of formula XXXIII include repeat units derived from N-vinylpyrrolidone, which forms PVP homopolymers and vinylpyrrolidone copolymers, or N-vinylpyrrolidone substituted with hydrophilic substituents such as phosphorylcholine.

Polyamides can also be copolymers containing cyclic amide, acyclic amide repeating units, or copolymers containing both cyclic amide and acyclic amide repeating units. Additional repeating units may be formed from monomers selected from hydroxyalkyl(meth)acrylates, alkyl(meth)acrylates, or other hydrophilic monomers, and siloxane-substituted acrylates or methacrylates. Any of the monomers listed above as acceptable hydrophilic monomers may be used as a comonomer to form additional repeating units. Specific examples of additional monomers that can be used to form polyamides include 2-hydroxyethyl methacrylate, vinyl acetate, acrylonitrile, hydroxypropyl methacrylate, 2-hydroxyethyl acrylate, methyl methacrylate and hydroxybutyl methacrylate, GMMA, PEGS, and the like, and mixtures thereof. Ionic monomers may also be included. Examples of ionic monomers include acrylic acid, methacrylic acid, 2-methacryloyloxyethylphosphorylcholine, 3-(dimethyl(4-vinylbenzyl)ammonio)propane-1-sulfonate (DMVBAPS), 3-((3-acrylamidopropyl)dimethylammonio)propane-1- sulfonate (AMPDAPS), 3-((3-methacrylamidopropyl)dimethylammonio)propane-1-sulfonate (MAMPDAPS), 3-((3-(acryloyloxy)propyl)dimethylammonio)propane-1-sulfonate (APDAPS), methacryloyloxy)propyl) dimethylammonio)propane-1-sulfonate (MAPDAPS).

The reactive composition may contain both an acyclic polyamide and a cyclic polyamide or their copolymers. The acyclic polyamide can be any of the acyclic polyamides described herein or their copolymers, and the cyclic polyamide can be any of the cyclic polyamides described herein or their copolymers. The polyamide may be selected from the group consisting of polyvinylpyrrolidone (PVP), polyvinylmethacetamide (PVMA), polydimethylacrylamide (PDMA), polyvinylacetamide (PNVA), poly(hydroxyethyl(meth)acrylamide), polyacrylamide, and copolymers and mixtures thereof.

Wetting agents can be derived from DMA, NVP, HEMA, VMA, NVA, and combinations thereof. Wetting agents can also be reactive components, as defined herein, if they contain polymerizable groups, for example, by an acylation reaction between the hydroxyl pendant groups on the HEMA repeat units of the internal wetting agent and methacryloyl chloride or methacryloyl anhydride. Other ways of functionalization will be apparent to those skilled in the art.

Such internal wetting agents are described in US Pat.

Substantially reactive components in a reactive composition may be dispersed or dissolved in a diluent. Acceptable diluents are known in the art and can be easily determined by a person skilled in the art. For example, diluents suitable for the preparation of silicone hydrogels are described in WO 03/022321 and US6,020,445, the descriptions of which are incorporated herein by reference.

Classes of acceptable diluents for silicone hydrogel reactive mixtures include alcohols having 2 to 20 carbon atoms, amides having 10 to 20 carbon atoms derived from primary amines, and carboxylic acids having 8 to 20 carbon atoms. Primary and tertiary alcohols are preferred. Preferred classes include alcohols having 5 to 20 carbon atoms and carboxylic acids having 10 to 20 carbon atoms.

Specific diluents that may be used include 1-ethoxy-2-propanol, diisopropylaminoethanol, isopropanol, 3,7-dimethyl-3-octanol, 1-decanol, 1-dodecanol, 1-octanol, 1-pentanol, 2 -pentanol, 1-hexanol, 2-hexanol, 2-octanol, 3-methyl-3-pentanol, tert-amyl alcohol, tert-butanol, 2-butanol, 1-butanol, 2-methyl-2-pentanol, 2- propanol, 1-propanol, ethanol, 2-ethyl-1-butanol, (3-acetoxy-2-hydroxypropyloxy)propylbis(trimethylsiloxy)methylsilane, 1-tert-butoxy-2-propanol, 3,3-dimethyl-2-butanol , tert-butoxyethanol, 2-octyl-1-dodecanol, decanoic acid, octanoic acid, dodecanoic acid, 2-(diisopropylamino)ethanol, mixtures thereof, etc.

Preferred diluents include 3,7-dimethyl-3-octanol, 1-dodecanol, 1-decanol, 1-octanol, 1-pentanol, 1-hexanol, 2-hexanol, 2-octanol, 3-methyl-3-pentanol , 2-pentanol, tert-amyl alcohol, tert-butanol, 2-butanol, 1-butanol, 2-methyl-2-pentanol, 2-ethyl-1-butanol, ethanol, 3,3-dimethyl-2-butanol, 2-octyl-1-dodecanol, decanoic acid, octanoic acid, dodecanoic acid, mixtures thereof, etc.

More preferred diluents include 3,7-dimethyl-3-octanol, 1-dodecanol, 1-decanol, 1-octanol, 1-pentanol, 1-hexanol, 2-hexanol, 2-octanol, 1-dodecanol, 3- methyl 3-pentanol, 1-pentanol, 2-pentanol, tert-amyl alcohol, tert-butanol, 2-butanol, 1-butanol, 2-methyl-2-pentanol, 2-ethyl-1-butanol, 3.3 -dimethyl-2-butanol, 2-octyl-1-dodecanol, mixtures thereof, etc.

Suitable diluents for silicone-free reactive formulations include glycerin, ethylene glycol, ethanol, methanol, ethyl acetate, methylene chloride, polyethylene glycol, polypropylene glycol, low number average molecular weight polyvinylpyrrolidone (PVP) such as those described in US Pat. US 5,039,459, including but not limited to boric acid esters of dihydric alcohols, combinations thereof, and the like.

Mixtures of diluents may be used. Diluents can be used in amounts of not more than about 55% of the mass. based on the weight of all components of the reactive composition. More preferably, the diluent is used in amounts less than about 45% wt., even more preferably in amounts from about 15% wt. and up to 40% of the mass. based on the weight of all components in the reactive composition.

In a preferred aspect, the cross-linked substrate network according to the invention may be a silicone hydrogel (comprising covalently linked, activated free radical polymerization initiators such as MAPO groups) and the graft composition may form, after polymerization, a hydrophilic graft material (which may optionally be charged) , for example, containing poly (N, N-dimethylacrylamide) (PDMA), polymerized polyethylene glycol monomethacrylate (for example, having a number average molecular weight from about 300 to about 1000) (poly (mPEG)), a copolymer of 2-hydroxyethyl methacrylate and methacrylic acid, 2- (methacryloyloxy)ethyl (2-(trimethylammonio)ethyl) phosphate (MPC). Such grafted polymer networks may exhibit improved biocompatibility and biometric performance when used in ophthalmic devices.

The cross-linked substrate network can be a conventional hydrogel (for example, containing a copolymer of 2-hydroxyethyl methacrylate and methacrylic acid and containing MAPO groups), and the graft composition after polymerization forms a hydrophilic graft material (which may optionally be charged), such as a polyamide. Examples include PDMA, polyvinylpyrrolidone (PVP), poly(N-vinyl N-methylacetamide) (PVMA) and their copolymers. Such grafted polymer networks may exhibit improved biocompatibility and biometric performance, for example, when used in ophthalmic devices.

The cross-linked substrate network may be a conventional hydrogel (eg, a copolymer of 2-hydroxyethyl methacrylate and methacrylic acid and containing MAPO groups), and the graft composition after polymerization forms a hydrophobic siloxane-containing material. Such grafted polymer networks can exhibit desirable physical and mechanical properties such as oxygen gas permeability (Dk) and elastic modulus, as well as improved biocompatibility and ease of handling.

For ophthalmic devices, such as contact lenses, that contain one or more silicone-containing components, the silicone-containing component(s) may preferably be present in amounts of no more than about 95% by weight, or from about 10 to about 80 , or from about 20 to about 70% of the mass. based on all reactive components present, including the first reactive composition and the second reactive composition. Suitable hydrophilic components may preferably be present in amounts of from about 10 to about 60% by weight, or from about 15 to about 50% by weight, or from about 20 to about 40% by weight. based on all reactive components present, including the first reactive composition and the composition for grafting.

It should be noted that additional, optional steps may be included in the process for preparing the polymer compositions of the invention. For example, after step (b), an ink or dye may be added to the cross-linked substrate network. Subsequently, the remaining steps may be carried out (step (c), etc.). This allows the ink or dye to be placed between the two layers of the grafted polymer network.

Moreover, the ophthalmic device formed using the above method can be further modified by one or more chemical reactions between the grafted compositions and other reagents to introduce other functional groups or change surface properties. For example, grafting poly(2-hydroxyethyl methacrylate) into a cross-linked substrate network provides hydroxyl groups that can be further reacted (eg, via acylation reactions) with other molecules that provide additional elements for the graft composition and/or end product. Such molecules can be UV and visible blockers, dyes, pigments, biologically active compounds such as peptides, prodrugs, etc. Grafting polyacrylic acid into a cross-linked substrate network provides carboxylate groups that can be further introduced into the reaction (for example , using active ester techniques) with other molecules, as already mentioned above. Moreover, in the case where a contact lens is prepared from silicone hydrogel as a cross-linked substrate network and subsequently grafted with polyacrylic acid, polymethacrylic acid, poly(glycidyl methacrylate) or their copolymers, the resulting poly(acid/epoxide) coated or treated contact lens can be used. in various layer-by-layer coating techniques to modify the surface properties of a contact lens.

For ophthalmic devices such as contact lenses, the cross-linked substrate network is preferably a silicone hydrogel with a balance of properties that makes such devices desirable. These properties include water content, turbidity, contact angle, elastic modulus, oxygen permeability, lipid uptake, lysozyme uptake, and PQ1 uptake. Examples of preferred properties are listed below. All values listed are preceded by the "about" modifier, and ophthalmic devices can have any combination of the following properties:

Water content: at least 20% or at least 25%

Haze: 30% or less or 10% or less

Dynamic contact angle (DCA (°)): 100° or less or 50° or less

Modulus of elasticity (psi): 120 or less, or 80 to 120

Oxygen permeability Dk (barrers): at least 80 or at least 100 or at least 150 or at least 200

Elongation at break: at least 100

For ionic silicone hydrogels, the following properties may also be preferred (in addition to those listed above):

Lysozyme uptake (µg/lens): at least 100 or at least 150 or at least 500 or at least 700

Polyquaternium-1 (PQ1) uptake (%): 15 or less, or 10 or less, or 5 or less

Finished ophthalmic devices can be obtained using a variety of techniques. For example, in the case of hydrogel contact lenses, the first reactive composition described above may be cured in a mold or formed by spin or static casting. Spin casting methods are described in US Pat. Nos. 3,408,429 and 3,660,545, and static casting methods are described in US Pat. In one embodiment, the contact lenses of the present invention are formed by direct molding of hydrogels, which is economical and allows precise control of the final shape of hydrated contact lenses. For this method, the first reactive composition is placed in a mold having the desired shape, and the reactive composition is subjected to the conditions described above, whereby the reactive components polymerize to form a cross-linked substrate network in the approximate shape of the final desired product.

The cross-linked substrate network formed after such curing can be subjected to extraction to remove unreacted components and remove the cross-linked substrate network from the contact lens mold. Subsequently, the cross-linked substrate network can be immersed in the grafting composition (which may optionally contain a diluent) for a time sufficient to allow the reactive composition to diffuse into the cross-linked substrate network to the desired level. The suspension is then irradiated to form a graft product and the contact lenses can subsequently be extracted to remove unreacted components.

Extraction of the cross-linked substrate network and contact lens can be done using conventional extraction fluids such as organic solvents such as alcohols, or extraction can be done using aqueous solutions. Aqueous solutions are solutions containing water. Aqueous solutions may contain at least about 30% of the mass. water, at least about 50% of the mass. water, at least about 70% of the mass. water or at least about 90% of the mass. water.

Extraction can be carried out, for example, by dipping the cross-linked substrate network or contact lens into an aqueous solution or exposing the material to a stream of an aqueous solution. The extraction may also include, for example, one or more of: heating the aqueous solution; stirring the aqueous solution; increasing the level of the auxiliary release agent in the aqueous solution to a level sufficient to remove the cross-linked substrate network from the mould; mechanical or ultrasonic mixing; and introducing at least one leaching aid into the aqueous solution to a level sufficient to facilitate efficient removal of unreacted components from the cross-linked substrate network or contact lens. The above processes can be carried out sequentially or continuously with or without additional exposure to heating, stirring, or both.

Some embodiments may also include the use of physical agitation to facilitate leaching and recovery. For example, the part of the mold for casting the cross-linked substrate web to which the cross-linked substrate web is attached can be subjected to vibration or back and forth movement in an aqueous solution. Other embodiments may include passing ultrasonic waves through an aqueous solution.

Contact lenses can be sterilized by known means such as, but not limited to, autoclaving.

Some embodiments of the invention will be described in detail in the following examples.

EXAMPLES

Contact lens diameter (DM) was measured on a calibrated Van Keuren micro-optical comparator equipped with Mitutoyo digital micrometer heads. The contact lens was placed concave side down in a crystal cell completely filled with borate buffered storage solution. The lid was placed on the cell, removing all the air from under it. Subsequently, the cell was placed on the comparator stage and the lens image was focused and aligned so that one edge of the lens touched the center line on the screen. The first edge was marked, the lens was moved along the diameter until the second edge touched the center line on the screen, and subsequently the second edge was marked by pressing the data button again. As a rule, two diameter measurements are taken and the average value is reported in the data sheets.

The water content (WC) was measured gravimetrically. The lenses were kept in the storage solution for 24 hours. Each of the three test lenses is removed from the storage solution using a sponge-tipped applicator and placed on blotting wipes moistened with the storage solution. Both sides of the lens are blotted with a napkin. Using tweezers, the lenses to be tested are placed on a tared balance pan and weighed. Two more sets of samples are prepared and weighed. All mass measurements were repeated three times, and the average value of the obtained values was used in further calculations. The wet weight is defined as the total weight of the weighing pan and wet lenses minus the weight of the weighing pan alone.

Dry weight was measured by placing the sample dishes in a vacuum oven that was preheated to 60°C for 30 minutes. Vacuum was applied until the pressure reached at least 1 inch Hg. Art.; lower pressures are acceptable. The vacuum valve and pump are turned off and the lenses are dried for at least 12 hours, usually overnight; Open the purge valve to allow dry air or dry nitrogen to enter. Furnaces allow to reach atmospheric pressure. The bowls are removed and weighed. Dry weight is defined as the total weight of the weighing pan and dry lenses minus the weight of the weighing pan alone. The water content of the test lens was calculated as follows: % water content = (wet weight - dry weight) / wet weight × 100. The average value and standard deviation for the water content were calculated and the average value was reported as the percentage of water in the test lens.

The weight gain of the grafted lens was calculated from the average dry weight of the grafted lens minus the average dry weight of the lens from the substrate and was expressed as a percentage. Both the grafted lens and the substrate lens were kept in deionized water for several hours to remove any residual salts. Typically, at least three lenses are weighed and averaged for each sample.

The refractive index (RI) of the contact lens was measured on a Leica ARIAS 500 Abbe refractometer in manual mode or on a Reichert ARIAS 500 Abbe refractometer in automatic mode with a gap between prisms of 100 microns. The instrument was calibrated with deionized water at 20°C (+/-0.2°C). The prism assembly was opened and the lens to be tested was placed on the lower prism between the magnetic points closest to the light source. If the lens was dry, a few drops of saline were applied to the lower prism. The front curved surface of the lens was placed opposite the lower prism. The prism assembly was then closed. After adjusting the controls until a shadow line appeared in the sighting field, the refractive index was measured. The RI measurement was performed for the five tested lenses. The average value of RI calculated from the results of five measurements was recorded as the refractive index together with its standard deviation.

Oxygen permeability (Dk) was measured by the polarographic method essentially described in ISO 9913-1:1996 and ISO 18369-4:2006, but with the following modifications. The measurement was carried out in an environment containing 2.1% oxygen, created by installing nitrogen and air inlets on the test chamber, set to the appropriate gas flow, for example, 1800 ml/min nitrogen and 200 ml/min air. The t/Dk value is calculated using the corrected oxygen concentration. Borate buffered saline was used. Dark current was measured using a clean humidified nitrogen environment instead of using MMA lenses. The lenses were not used before the measurement. Instead of using lenses of different thicknesses (t), measured in centimeters, four lenses were stacked on top of each other. Instead of a flat sensor, a curved sensor with a radius of 7.8 mm was used. Calculations for a sensor with a radius of 7.8 mm and a relative air flow of 10% (vol./vol.) were carried out as follows:

Dk/t = (measured current - dark current) × (2.97 × 10 ^-8 ml O2 / (µA-sec-cm ² -mmHg)

The edge correction depended on the Dk value of the material.

For all Dk values less than 90 barrer:

t/Dk (edge correction) = (1 + (5.88 × t)) × (t/Dk)

For Dk values from 90 to 300 bbl:

t/Dk (edge correction) = (1 + (3.56 × t)) × (t/Dk)

For Dk values greater than 300 barrer:

t/Dk (edge correction) = (1 + (3.16 × t)) × (t/Dk)

Dk values without edge correction were calculated from the reciprocal of the slope obtained by linear regression analysis of the data, in which the variable x was the thickness of the central part in centimeters, and the variable y was the value of t/Dk. On the other hand, the edge-corrected Dk (EC Dk) values were calculated from the reciprocal of the slope obtained by linear regression analysis of the data, in which the x variable was the center thickness in centimeters and the y variable was the t/Dk value corrected for edge. The measured Dk values were given in barrels.

Lens wettability was determined by the modified Wilhelmy plate method using a calibrated Kruss K100 tensiometer at room temperature (23 ± 4 °C) and using buffered saline without surfactant as a probe solution. All equipment must be clean and dry; vibrations around the tool during testing should be kept to a minimum. The wettability is usually given in the form of contact angle (Kruss DCA). The tensiometer was equipped with a humidity generator, and a temperature and humidity sensor was placed in the tensiometer chamber. Relative humidity is maintained at 70 ± 5%. The experiment was carried out by immersing a lens sample of known perimeter in a storage solution of known surface tension and measuring the wetting force on the sample with accurate weights. The contact angle when the storage solution leaked onto the lens was determined from the force data obtained by immersing the sample. The drip contact angle was determined from the force data obtained when the sample was removed from the liquid. The Wilhelmy plate method is based on the following formula: Fg=γρcosθ - B, where F is the wetting force between the liquid and the lens (mg), g is the acceleration due to gravity (980.665 cm/s ² ), γ is the surface tension of the probe liquid (dynes/cm ), ρ is the liquid/lens meniscus perimeter of the contact lens (cm), θ is the dynamic contact angle (degrees) and B is the hydrostatic lift (mg). The value of B is zero at zero immersion depth. Typically, the test strip is cut from the central region of the contact lens. Each strip was approximately 5 mm wide and 14 mm long, attached to a metal clip with plastic tweezers, pierced with a metal wire hook, and soaked in the storage solution for at least 3 hours. Then, four cycles of measurement were carried out with each sample, and the results were averaged to obtain the contact angles of the lenses during leakage and runoff. Typical measured speeds were 12 mm/min. The samples were completely immersed in the storage solution during data collection and analysis without touching the metal clamp. The values from five individual lenses were averaged to obtain the reported contact angle values for the inflow and outflow of the experimental lens.

Lens wettability was determined using the fixed drop method using a KRUSS DSA-100TM instrument at room temperature and using deionized water as a probe solution (fixed drop). Test lenses were rinsed in deionized water to remove any remaining storage solution. Each test lens was placed on blotting lint-free wipes moistened with storage solution. Both sides of the lens were blotted with a tissue to remove water from the surface without drying the lens. To ensure proper alignment, the lenses were placed "cupped" side down on the convex surface of plastic molds for molding contact lenses. The plastic mold and lens were placed in the fixed drop tool holder, ensuring proper centering of the syringe. Using the DSA 100 drop shape analysis software, a drop of 3-4 µl of deionized water was formed at the end of the syringe, making sure that the liquid drop hung down without touching the lens. The drop was smoothly lowered onto the surface of the lens by moving the needle down. The needle was withdrawn immediately after the drop was dispensed. The liquid drop was allowed to equilibrate on the lens for 5 to 10 seconds and the contact angle between the drop image and the lens surface was measured. Three to five lenses were typically evaluated and the average contact angle reported.

The mechanical properties of the contact lenses were measured using a tensile testing machine such as an Instron Model 1122 or 5542 equipped with strain gauge controls and pneumatic grippers. A minus one diopter lens is the preferred lens geometry due to the uniform thickness of the central profile. A -1.00 power lens cut, 0.522" long, 0.276""eye" width, and 0.213""neck" width, dumbbell-shaped sample was placed in the jaws and stretched at a constant pull rate of 2 inches/minute until breakage. Before testing, the thickness of the center of the dumbbell-shaped sample was measured using an electronic thickness gauge. The initial length of the sample (Lo) and the length of the sample at break (Lf) were measured. At least five samples of each composition were measured and the averages were used to calculate the percent elongation at break: percent elongation = ((Lf - Lo) / Lo) × 100. Tensile modulus (M) was calculated as the slope of the initial linear section of the stress-tension curve; the units of modulus of elasticity are pounds per square inch (psi). Tensile strength (TS) was calculated from the peak load and the original cross-sectional area: tensile strength=peak load divided by the original cross-sectional area; the units of measure for tensile strength are psi. The tensile stiffness was calculated from the energy at break and the initial volume of the sample: tensile stiffness=energy at break divided by the initial volume of the sample; the units of tensile stiffness are inch-lb/in ³ . Elongation at break (ETB) was also recorded as a percentage of elongation at break.

PQ1 absorbance (PQ1) was measured chromatographically. The HPLC analyzer was calibrated using a series of PQ1 standard solutions at concentrations of 2, 4, 6, 8, 12, and 15 µg/mL. The lenses were placed in polypropylene contact lens cases with 3 ml of Optifree Replenish or similar lens solution (PQ1 concentration = 10 micrograms/ml) commercially available from Alcon. A control lens case was also prepared containing 3 ml of solution without a contact lens. Lenses and control solutions were kept at room temperature for 72 hours. 1 ml of the solution was removed from each of the samples and controls and mixed with trifluoroacetic acid (TFA) (10 μl). Analysis was performed using HPLC/Evaporative Light Scattering Detector (ELSD) and Phenomenex Luna C5 columns (particle size 4.6 mm × 5 mm; 5 µm) using the following equipment and conditions: Agilent 1200 HPLC analyzer or equivalent with ELSD operating at temperature T=100 °C, gain=12, pressure=4.4 bar, filter time constant=3 s; ELSD parameters may vary from instrument to instrument; using water (0.1% TFA) as mobile phase A and acetonitrile (0.1% TFA) as mobile phase B, column temperature 40 °C and injection volume 100 µl. The elution profile shown in Table A was used. A calibration curve was generated by plotting the peak area versus the concentration of the PQ1 standard solutions. Then the concentration of PQ1 in the sample was calculated by solving a quadratic equation representing the calibration curve. Three lenses were used for each analysis and the results were averaged. The PQ1 uptake is given as the percentage loss of PQ1 after soaking with the lens compared to the amount of PQ1 present in the control sample without the lens.

Table A. HPLC Elution Profile

Time (minutes) %A %B Flow rate (ml/min) 0.00 100 0 1.2 1.00 100 0 1.2 5.00 0 100 1.2 8.50 0 100 1.2 8.60 100 0 1.2 11.00 100 0 1.2

The amount of cholesterol absorbed by the contact lens was determined by LC-MS (lipids). The lenses were soaked in a cholesterol solution and subsequently extracted with dichloromethane. The dichloromethane extract was evaporated and reconstituted in a heptane/isopropanol mixture followed by LC-MS analysis. The results obtained are given in micrograms of cholesterol per lens. To improve the accuracy and reliability of the method used the internal standard of deuterated cholesterol.

A cholesterol stock solution was prepared by placing 15.0 ± 0.5 milligrams of cholesterol into a 10 ml wide-mouthed glass volumetric flask, followed by dilution with isopropanol.

A cholesterol solution for lens soaking was prepared by placing 0.430 ± 0.010 grams of lysozyme (purity = 93%), 0.200 ± 0.010 grams of albumin, and 0.100 ± 0.010 grams of β-lactoglobulin in a 200 ml glass volumetric flask, adding approximately 190 milliliters of phosphate-salt to the flask. buffer solution (PBS) and stirring to dissolve the contents. Then 2 ml of cholesterol stock solution was added and diluted to final volume with PBS. The volumetric flask was capped and shaken well. The concentration of the cholesterol solution for soaking the lenses was about 15 µg/ml. Note. The masses of these components can be adjusted to account for changes in purity from batch to batch so as to obtain target concentrations.

Six contact lenses were removed from their packages and blotted with lint-free paper towels to remove excess storage solution. The lenses were placed in six separate 8 ml glass vials (one lens per vial) and 3.0 ml of cholesterol solution was added to each vial to soak the lenses. The flasks were capped and placed in a New Brunswick Scientific shaker-incubator for 72 hours at 37°C and 100 rpm. After incubation, each lens was washed three times with PBS in 100 ml beakers and placed in a 20 ml scintillation vial.

5 ml of dichloromethane and 100 µl of an internal standard solution were added to each scintillation vial with a lens. After a minimum of 16 hours of extraction, the settled supernatant was transferred to a disposable 5 ml glass culture tube. The tube was placed in a Turbovap and the solvent was completely evaporated. Then, 1 ml of diluent was added to the culture tubes to redissolve the contents. The above diluent was a mixture of heptane and isopropanol in a ratio of 70:30 (v/v). The diluent was also the mobile phase. The resulting solution was carefully transferred to an autosampler vial and prepared for LC-MS analysis.

An internal standard stock solution was prepared by dosing approximately 12.5+2 mg of deuterated cholesterol (2,2,3,4,4,6-d ₆ -cholesterol) into a 25 ml volumetric flask, followed by dilution with diluent. The concentration of the stock solution of the internal standard was approximately 500 μg/ml.

The internal standard solution was prepared by placing 1.0 ml of the stock solution of the internal standard in a 50 ml volumetric flask, followed by dilution with diluent to the final volume. The concentration of this intermediate internal standard solution was approximately 10 µg/mL.

The reference standard stock solution was prepared by dosing approximately 50+5 mg of cholesterol into a 100 ml volumetric flask, followed by dilution with diluent. The cholesterol concentration in this stock solution of the reference standard was approximately 500 μg/ml.

Working standard solutions were then prepared according to Table B by placing the appropriate amounts of the standard solutions into the 25 ml, 50 ml or 100 ml volumetric flasks listed. After adding the standard solutions to the volumetric flasks, the mixtures were diluted with diluent to final volume and mixed well.

Table B. Compositions of working standard solutions

Name
working
standard Volume of internal standard solution (ml) Volume of reference standard stock solution (µl) Finite
volume
(ml) Approximate
cholesterol concentration
(µg/ml) Standard 1 ten twenty 100 0.10 Standard 2 5 25 fifty 0.25 Standard 3 5 fifty fifty 0.50 Standard 4 5 100 fifty 1.00 Standard 5 2.5 125 25 2.50 Standard 6 2.5 250 25 5.00

Conducted the following LC-MS analysis: Made 6 injections of standard 4 to assess the suitability of the system. To pass the system suitability test, the relative standard deviation (RSD%) of the peak areas for working standards and internal standards must be < 5%, and the RSD% of their peak area ratios must be < 7%. Introduced working standards 1-6 to create a calibration curve. The square of the correlation coefficient (r ² ) should be > 0.99. Introduced test samples, followed by the introduction of the control standard (standard 4). The peak area ratio of the control standard should not differ by more than ±10% from the average peak area ratio of the samples entered for system validation.

A calibration curve was built by plotting the peak area ratio (reference standard/internal standard) that corresponds to the concentration of each working standard solution. The cholesterol concentration in the sample is calculated by solving a quadratic equation. Standard LC/MS analysis equipment and parameters are listed below and are summarized in Tables C and D. Instrument setup parameters can be changed with each setup of the mass spectrometer.

Evaporation conditions in the Turbovap system:

Temperature: 45°C

Time: 30 minutes or more to dry

Gas: nitrogen at 5 psi

HPLC conditions:

HPLC: Thermo Accela HPLC or equivalent

HPLC column: Agilent Zorbax NH2 (4.6 mm × 150 mm; particle size 5 µm)

Mobile phase: 70% heptane and 30% isopropanol

Column temperature: 30 °C

Injected sample volume: 25 µl

Flow rate: 1000 µl/min

Table C. Mass Spectrometry Conditions

Thermo Finnigan TSQ Quantum Ultra MS Settings Meaning Ionization APCI Polarity Positive Scan type SIM APCI Probe Position D Mass (m/z) of reference standards 369.2 Mass (m/z) internal standards 375.3 Mass Width (m/z) 1.0 Scan time (s) 0.10 Data type center of gravity Q3 Peak Width (FWHM) 0.40 Skimmer Offset (V) ten

Table D. Settings

Instrument settings Meaning Discharge current (conventional units) twenty Capillary temperature (°C) 240 Evaporator temperature (°C) 500 Displacement of tube with lens (V) 68 Shielding gas pressure (conventional units) twenty Auxiliary gas consumption (conventional units) fifteen

The level of absorption of lysozyme by the contact lens was measured by HPLC in the UV range. Lysozyme uptake was determined as the difference between the lysozyme content in phosphate buffered saline (PBS) prior to contact lens immersion and the concentration in the test solution after 72 hours of lens immersion at 37°C.

A lysozyme solution for soaking was prepared by placing 0.215 ± 0.005 grams of lysozyme (purity=93%) in a 100 ml volumetric flask, followed by the addition of 50 ml of PBS to dissolve the lysozyme with stirring, followed by dilution to final volume with PBS. The resulting lysozyme soak solution was filtered/sterilized using a Millipore Stericup filtration device. The concentration of the lysozyme soak solution was about 2000 µg/ml. The mass of lysozyme can be adjusted to account for changes in purity from lot to lot, so as to give a concentration of 2000 µg/ml.

Three contact lenses were removed from their packages and blotted with lint-free paper towels to remove excess storage solution. The lenses were placed in three separate 8 ml glass vials (one lens per vial). 1.5 ml of lysozyme solution for lens soaking was added to each vial. The vials were capped and inspected to ensure that each lens was completely immersed in the soak solution. As controls, three separate 8 ml glass vials were filled with 1.5 ml of lysozyme solution for lens soaking. The samples were then incubated in a New Brunswick Scientific Incubator Shaker for 72 hours at 37°C and 100 rpm.

The diluent was prepared by mixing 900 ml of water, 100 ml of acetonitrile and 1 ml of trifluoroacetic acid in a 1 liter glass bottle.

A stock solution of lysozyme was prepared by placing 0.240 ± 0.010 grams of lysozyme (purity=93%) in a 100 ml volumetric flask followed by dilution with diluent to final volume. The concentration of the stock solution of lysozyme was approximately 2200 μg/ml.

As shown in Table E, a series of working standards were prepared by mixing appropriate amounts of lysozyme stock solution with diluent using 5 ml volumetric vials.

Table E. Working Standards

Name
working
standard Volume of mother liquor
(ml) Finite
volume
(ml) Approximate
lysozyme concentration
(µg/ml) Standard 1 1.135 5 500 Standard 2 1.815 5 800 Standard 3 2.725 5 1200 Standard 4 3.635 5 1600 Standard 5 4,540 5 2000 Standard 6 (uterine) - - 2200

A 10% (v/v) solution was prepared by adding 1 ml trifluoroacetic acid (TFA) to a 10 ml glass volumetric flask followed by dilution with water for HPLC. Samples for UV HPLC analysis were prepared as follows: (1) place 1000 µl of test sample and 10 µl of 10% TFA solution into the autosampler vial or (2) place 1000 µl of reference standard and 10 µl of diluent reference standard into the autosampler vial sampler.

The analysis included the following steps: Performed 6 injections of standard 4 to evaluate system suitability. RSD% peak areas and retention time must be < 0.5% to pass the system suitability test. Introduced working standards 1-6 to create a calibration curve. The square of the correlation coefficient (r ² ) should be > 0.99. Introduced test samples, followed by the introduction of the control standard (standard 4). The peak area of the control standard shall be ±1% of the mean peak areas of the samples entered for system validation.

A calibration curve was built by plotting the peak area value corresponding to the concentration of each working lysozyme standard solution. The concentration of lysozyme in the test sample was calculated by solving a linear equation. Standard equipment and options are listed below or listed in Table F.

Instrument: Agilent 1200 UV analyzer (or equivalent UV HPLC system)

Detection: UV at 280 nm (bandwidth 5 nm)

HPLC column: Phenomenex Luna C5 (50 x 4.6 mm) or Agilent PLRP-S (50 x 4.6 mm)

Mobile phase A: H2O (0.1% TFA)

Mobile phase B: Acetonitrile (0.1% TFA)

Column temperature: 40 °C

Injected sample volume: 10 µl

Table F. HPLC Conditions

Time (minutes) %A %B Flow rate (ml/min) 0.0 95 5 1.2 4.0 5 95 1.2 4.1 95 5 1.2 6.5 95 5 1.2

Haze can be measured by placing a hydrated test lens in a borate-buffered saline solution in a clear glass cell at room temperature against a flat black background, illuminated from below with a fiber optic lamp (Dolan-Jenner PL-900 fiber optic light source with a 0.5 diameter waveguide light guide). inch) at an angle of 66° perpendicular to the lens cell and shooting from above, perpendicular to the lens cell, a video camera (DVC 1300C:19130 RGB camera or equivalent with zoom lens) mounted 14 mm above the lens holder. Background scatter was subtracted from the scatter of the test lens by subtracting the blank cell image of borate buffered saline (baseline) using EPIX XCAP V 3.8 software. By adjusting the light intensity to be in the range from 900 to 910 of the average value on the gray scale, the value of the upper limit of scattering (frosted glass) was obtained. The amount of background scattering was measured using a saline-filled glass cell. The subtracted stray light image is quantitatively analyzed by integration over the central 10 mm lens and then compared to a ground glass standard. By adjusting the light intensity/power settings, an average gray scale value was obtained in the range of 900 to 910 for the ground glass standard; at these settings, the average gray value for the baseline was in the range of 50-70. The average gray scale value for the baseline and for the ground glass standard was recorded and used to construct a scale from zero to 100, respectively. In the gray scale analysis, the mean values and their standard deviations for baseline, ground glass, and each lens tested were recorded. For each lens, a scaling value was calculated according to the following equation: the scaling value is equal to the difference between the mean greyscale values of the lens and baseline divided by the difference of the mean greyscale values of ground glass and baseline, multiplied by 100. Three to five test lenses were analyzed and the results averaged.

The invention will be described below with reference to the following examples. Before proceeding to the description of several embodiments of the invention, it should be understood that the invention is not limited to the characteristics of the design or the steps of the method presented in the following description. The invention also has other embodiments and may be practiced or carried out in various ways.

In the examples, the following abbreviations will be used, the meanings of which are given below.

NVP: N-vinylpyrrolidone (Acros or Aldrich)

DMA: N,N-dimethylacrylamide (Jarchem)

HEMA: 2-hydroxyethyl methacrylate (Bimax)

HPMA: 2-hydroxypropyl methacrylate

AA: acrylic acid

MAA: methacrylic acid (Acros)

MPC: 3,5,8-trioxa-4-phosphonoundec-10-en-1-aminium, 4-hydroxy-N, N,N,10-tetramethyl-9-oxo internal salt, 4-oxide; CAS 67881-98-5

mPEG 360: polyethylene glycol methacrylate (Aldrich) (M _n =360 g/mol)

mPEG 475: polyethylene glycol methyl ether methacrylate (Aldrich) (M _n =475 g/mol)

mPEG 500: polyethylene glycol methyl ether methacrylate (Aldrich) (M _n =500 g/mol)

mPEG 950: polyethylene glycol methacrylate (Aldrich) (M _n =950 g/mol)

PVMA: poly(N-vinyl-N-methylacetamide)

PVP: poly(N-vinylpyrrolidone) (ISP Ashland)

EGDMA: ethylene glycol dimethacrylate (Esstech)

TEGDMA: tetraethylene glycol dimethacrylate (Esstech)

TMPTMA: trimethylol propane trimethacrylate (Esstech)

MBA: methylenebisacrylamide (Aldrich)

TAC: triallyl cyanurate (Polysciences)

Tegomer V-Si 2250: diacryloxypolydimethylsiloxane (Evonik)

Irgacure 819: bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide (BASF or Ciba Specialty Chemicals)

Irgacure 1870: mixture of bis(2,6-dimethoxybenzoyl)-2,4,4-trimethylpentylphosphine oxide and 1-hydroxycyclohexylphenylketone (BASF or Ciba Specialty Chemicals)

IEM: 2-isocyanatoethyl methacrylate

mPDMS: mono-n-butyl and monomethacryloxypropyl terminated polydimethylsiloxane (molecular weight 800-1000) (Gelest)

ac-PDMS: bis-3-acryloxy-2-hydroxypropyloxypropylpolydimethylsiloxane

HO-mPDMS: mono-n-butyl-terminated polydimethylsiloxane with mono-(2-hydroxy-3-methacryloxypropyl)propyl ether (molecular weight 400-1000) (Ortec or DSM-Polymer Technology Group)

TRIS: 3-methacryloxypropyltris(trimethylsiloxy)silane

TRIS-ac: 3-acryloxypropyltris(trimethylsiloxy)silane

TRIS-am: 3-acrylamidopropyl-tri(trimethylsiloxy)silane

SiMAA: 2-propenoic acid, 2-methyl-2-hydroxy-3-[3-[1,3,3,3-tetramethyl-1-[(trimethylsilyl)oxy]disiloxanyl]propoxy]propyl ester (Toray) or 3 -(3-(1,1,1,3,5,5,5-heptamethyltrisiloxan-3-yl)propoxy)-2-hydroxypropyl methacrylate or 2-hydroxy-3-[3-methyl-3,3-di(trimethylsiloxy )silylpropoxy]propyl methacrylate

Norbloc: 2-(2'-hydroxy-5-methacryloxyethylphenyl)-2H-benzotriazole (Janssen)

HEMA Blue: 1-Amino-4-[3-(4-(2-methacryloyloxyethoxy)-6-chlorotriazin-2-ylamino)-4-sulfophenylamino]anthraquinone-2-sulfonic acid as described in US Pat. No. 5,944,853

DMPC: 1,2-dimyristoyl-sn-glycero-3-phosphocholine

L-PEG: N-(carbonyl-methoxy-polyethylene glycol-2000)-1,2-distearoyl-sn-glycero-3-phosphoethanolamine sodium salt

DIW: deionized water

IPA: isopropyl alcohol

PG: 1,2-propylene glycol

PEG 200: polyethylene glycol (Aldrich) (M _n =200 g/mol)

PEG 400: polyethylene glycol (Aldrich) (M _n =400 g/mol)

PS: Borate buffered storage solution: 18.52 grams (300 mmol) boric acid, 3.7 grams (9.7 mmol) sodium borate decahydrate and 28 grams (197 mmol) sodium sulfate were dissolved in enough deionized water to fill 2 liter volumetric flask.

FM-1: fluorescein methacrylate-3',6'-dihydroxy-3-oxo-3H-spiro[isobenzofuran-1,9'-xanthene]-5-ylmethacrylate (Polysciences)

FM-2: Fluoresceinacrylamide-N-(3',6'-dihydroxy-3-oxo-3H-spiro[isobenzofuran-1,9'-xanthene]-5-yl)acrylamide (Polysciences)

FM-3: Fluorescein methacrylamide-N-(3',6'-dihydroxy-3-oxo-3H-spiro[isobenzofuran-1,9'-xanthene]-5-yl)methacrylamide (Polysciences)

BC: plastic injection mold for base or back curvature made from PP, TT, Z or mixtures thereof

FC: plastic injection mold for front curvature made from PP, TT, Z or mixtures thereof

PP: polypropylene, which is a propylene homopolymer

TT: Tuftec which is a hydrogenated styrene-butadiene block copolymer (Asahi Kasei Chemicals)

Z: Zeonor which is a polycycloolefin thermoplastic polymer (Nippon Zeon Co Ltd)

RMM: reactive mixture of monomers

TL03 light sources: Phillips TLK 40W/03 or equivalent

WC: water content (% mass)

EC Dk: edge-corrected oxygen permeability (barrers)

M: modulus of elasticity (psi)

TS: tensile strength (psi)

ETB: elongation at break (%)

RI: refractive index

Stationary droplet: contact angle (degrees)

Example 1

The reaction monomer mixture was prepared by mixing the reactive components listed in Table 1. This composition was filtered through a 3 µm filter using a heated or unheated stainless steel or glass syringe, depending on the viscosity, and degassed by applying a vacuum (about 40 mmHg) at ambient temperature for about 45 minutes. Under an atmosphere of nitrogen gas and about 0.5 percent oxygen gas, 75 μl of the reaction mixture was dosed into a FC made from PP. BC made from Z was subsequently placed on FC. Eight trays, each containing eight lens mold assemblies, were irradiated for 10 minutes at 65°C using a 435 nm LED having an intensity at the tray surface of 5 mW/cm ² . The light source was placed above the pallets. Working under yellow light, the lenses were mechanically separated from the molds using a hand press and placed individually in tissue capsules ("Example 1. Substrates"). The typical yield was about 65 lenses without defects. Subsequently, the capsules containing the lenses were stored in amber plastic bottles until used in coating experiments. To prepare control lenses, some lenses were washed twice with 70% (v/v) aqueous IPA, twice with deionized water, and twice with borate buffered storage solution and subsequently stored in vials. After about two days of equilibration, the lenses were examined and autoclaved at 121°C for about 30 minutes (“Example 1 Controls”). The average lens diameter and water content are shown in Table 2.

Table 1

Component % wt. OH-mPDMS, n=4 54.89 DMA 19.53 HEMA eight PVP K90 12 TEGDMA 3.11 Norbloc 2.2 Irgacure 819 0.25 Blue HEMA 0.02

Examples 2-4

In a protective glovebox with a nitrogen gas atmosphere and an oxygen content of less than 0.2%, the lenses from Example 1 (“Example 1. Substrates”) were suspended in a 25% (v/v) solution of hydrophilic monomer and 0.10% (w/w) fluorescein methacrylate FM-1 in PEG 200 at a concentration of 1 lens/2 ml. Both lenses and hydrophilic monomer solutions were degassed before mixing for 15-30 minutes using vacuum (about 40 mmHg) and subsequently purged with nitrogen gas. The vials were capped, placed in a shaker bath and equilibrated at 38°C for about one minute. The caps were replaced with transparent plastic caps and the vials were irradiated with TL03 lamps (wavelength 380-470 nm; peak 420 nm) at room temperature for 15 minutes at an intensity of 4.5-5.0 mW/cm ² with stirring (120- 165 rpm). After irradiation, the lenses were removed and washed twice with 70% (v/v) aqueous IPA, twice with deionized water, and twice with borate buffered storage solution. The lenses were stored in vials. After about two days of equilibration, the lenses were inspected and autoclaved at 121°C for about 30 minutes. Average lens diameters, water content, dry weight changes, and coating thickness values are shown in Table 2 for examples of lens coatings using MPC, mPEG 360, and mPEG 500 as hydrophilic monomers. In all cases, grafted lens diameter, water content, and dry weight increased. compared to the control lens, which corresponds to the formation of a covalently grafted hydrophilic coating. According to confocal microscopy, the thickness of the coatings ranged from about 3 microns to about 6 microns. The lens has a central portion thickness of approximately 109 microns, thus an approximate penetration of about 2.8 to about 5.6%.

table 2

Example hydrophilic monomer Diameter (mm) Water content (% mass) Increase in dry weight (%) Coating thickness (µm), confocal microscopy Example 1. Controls - 13.05 34.2 - - Example 2 MPC 13.9 37.4 4.9 3.3 Example 3 MPEG 360 14.1 37.8 8.8 5.5 Example 4 MPEG500 14.4 40.2 13.3 6.2

A method of research using confocal microscopy (CFM). The hydrated surface of the grafted lens was positioned and subjected to confocal fluorescence microscopy using a Zeiss LSM 700 series confocal fluorescence microscope. Excitation wavelengths were 488 nm (2.0% laser power) and 555 nm (about 2.0% laser power); the radiation wavelength was about 512 nm; the scanning area was 128 × 128 microns; and the Z step width was 0.5 microns. Confocal microscopy showed fluorescence only in the surface layers of the grafted lenses, consistent with the grafting reaction occurring upon diffusion of the reactive monomer solution into the lens.

Example 5

Example 1 was repeated on a pilot production line instead of a glove box. The lenses were mechanically removed and stored for further grafting experiments ("Example 5 Substrates"). Some lenses were removed in IPA, hydrated and sterilized ("Example 5 Controls"). The physical and mechanical properties of these control lenses were measured and listed in Table 4.

Example 6

In a glove box with an inert atmosphere, in a plastic plate (12 wells per plate), 2 ml of 25% (w/w) degassed HEMA solution in PEG 400 was placed in each well and subsequently one lens of example 5 ("Example 5. Substrates") with the concave side up and left to float freely. The well plate was irradiated with a 420 nm LED having an intensity of 10 mW/cm ² on the plate surface at 35° C. for 4.5 minutes. Unlike examples 2-4, the coating process was carried out essentially without shaking. The lenses were transferred to a large vial containing 70% (v/v) IPA and swung for at least 12 hours and subsequently washed twice with DIW and twice with borate buffered storage solution. Finally, the lenses were sterilized by autoclaving at 121°C for about 30 minutes. After bringing to equilibrium for several days, the physical and mechanical properties of the lenses were measured; they are presented in table 4.

Example 7

Example 1 was repeated in a glovebox using a slightly different formulation from Table 3. Lenses were mechanically removed and stored for further grafting experiments ("Example 7 Substrates"). Some lenses were removed in IPA, hydrated and sterilized ("Example 7 Controls"). The physical and mechanical properties of these control lenses were measured and listed in Table 4.

Table 3

Component % wt. OH-mPDMS, n=4 54.89 DMA 21.14 HEMA eight PVP K90 12 TEGDMA 1.5 Norbloc 2.2 Irgacure 819 0.25 Blue HEMA 0.02

Example 8

In a glove box with an inert atmosphere in a plastic plate (12 wells per plate), 2 ml of a 25% (w/w) degassed solution of 50 : 50 (mol/mol) HEMA : MPC in PEG 400 was placed in each well and subsequently, one lens from Example 7 ("Example 7. Substrates") was placed in each well, concave side up, and left to float freely. The well plate was covered with a transparent plastic sheet and irradiated with a 420 nm LED having an intensity of 10 mW/cm ² on the plate surface at 35° C. for 4.5 minutes. Before irradiation, the lenses were aged for about 1-5 minutes. The lenses were transferred to a large vial containing 70% (v/v) IPA and swung for at least 12 hours and subsequently washed twice with DIW and twice with borate buffered storage solution. The lenses were cloudy after washing with aqueous IPA but became clear after IPA was removed with DIW and PS. Finally, the lenses were sterilized by autoclaving at 121°C for about 30 minutes. After bringing to equilibrium for several days, the physical and mechanical properties of the lenses were measured; they are presented in table 4.

Table 4

Dry lens weight (mg) Water content
(% mass) M
(psi) TS
(psi) ETB (%) R.I. Fixed drop
(°) Example 5 Controls 12 35 (0) 247(4) 113 (39) 91 (37) 1.4314 (0.0020) 55(7) Example 6 fourteen 34(1) 300 (22) 90 (26) 52 (18) 1.4481 (0.0030) 51 (10) Example 7 Controls 21 41(1) 123 (10) 100 (32) 184 (57) 1.4225 (0.0004) 59(3) Example 8 22 42 (0) 122 (12) 125 (25) 245 (36) 1.4262 (0.0015) 51 (10)

Example 9

In a glove box with an inert atmosphere in a plastic plate (12 wells per plate), 6 ml of 5%, 10%, 15% or 20% (w/w) degassed HEMA solution in PEG 400 and subsequently one lens from Example 5 (“Example 5. Substrates”) was placed in each well with the concave side up and left to float freely. The well plate was covered with a transparent plastic sheet and irradiated with a 420 nm LED having an intensity of 10 mW/cm ² on the plate surface at 35° C. for 4.25 minutes. For each coating formulation, the lenses were transferred to a large vial containing 70% (v/v) IPA for at least 12 hours (overnight) and subsequently washed twice with DIW and twice with borate buffered storage solution. Finally, the lenses were sterilized by autoclaving at 121°C for about 30 minutes.

Example 10 (possible use)

The reactive monomer mixtures were prepared by mixing the reactive components listed in Table 6. These formulations were filtered through a 3 µm filter using a heated or unheated stainless steel or glass syringe, depending on the viscosity, and degassed by applying a vacuum (about 40 mmHg) at ambient temperature for about 45 minutes. Under an atmosphere of nitrogen gas and about 0.5 percent oxygen gas, about 75 µl of the reactive mixture is dosed into an FC form made from Z or from a mixture of Z and TT in a ratio of 90:10 (w/w). Subsequently, BC made from PP or from a mixture of Z : PP 90 : 10 (w/w) is placed on the FC. Eight trays, each containing eight lens mold assemblies, are irradiated for 10 minutes at 65°C using a 435 nm LED having an intensity at the tray surface of 5 mW/cm ² . The light source is placed above the pallets. Working under yellow light, the lenses are mechanically separated from the molds using a hand press and placed individually in tissue capsules. Subsequently, the capsules containing the lenses are stored in amber plastic bottles until used in coating experiments ("Example 10A. Substrates" and "Example 10B. Substrates").

Table 6

Component Example 10A,
% wt. Example 10B,
% wt. OH-mPDMS (n=4) thirty thirty OH-mPDMS (n=15) thirty thirty Tegomer V-Si 2250 ten ten DMA ten ten HEMA 13.6 14.6 MAA one 0 MPEG950 3 3 Norbloc 1.98 1.98 Blue HEMA 0.02 0.02 CGI 819 0.4 0.4

In an inert atmosphere glove box, in a plastic plate (12 wells per plate), 2 ml of a 25% (w/w) degassed HPMA solution in PEG 400 was placed in each well and subsequently one lens of “Example 10A. Substrates" with the concave side up and left to float freely. The well plate is covered with a transparent plastic sheet and irradiated with a 420 nm LED having an intensity of 10 mW/cm ² on the plate surface at 35° C. for 4.5 minutes. The lenses are transferred to a large vial containing 70% (v/v) IPA and shaken for at least 12 hours and subsequently washed twice with DIW and twice with borate buffered storage solution. Finally, the lenses are sterilized by autoclaving at 121°C for about 30 minutes.

In an inert atmosphere glovebox, in a plastic plate (12 wells per plate), 2 ml of a 25% (w/w) degassed solution of AA in PEG 400 was placed in each well and subsequently one lens of “Example 10B. Substrates" with the concave side up and left to float freely. The well plate is covered with a transparent plastic sheet and irradiated with a 420 nm LED having an intensity of 10 mW/cm ² on the plate surface at 35° C. for 4.5 minutes. The lenses are transferred to a large vial containing 70% (v/v) IPA and shaken for at least 12 hours and subsequently washed twice with DIW and twice with borate buffered storage solution. Finally, the lenses are sterilized by autoclaving at 121°C for about 30 minutes.

In a glove box with an inert atmosphere, in a plastic plate (12 wells per plate), 2 ml of 25% (w/w) degassed AA solution and 0.1% (w/w) cross-linker are placed in each well. agent MBA in PEG 400, after which one lens from “Example 10B. Substrates" with the concave side up and left to float freely. The well plate is covered with a transparent plastic sheet and irradiated with a 420 nm LED having an intensity of 10 mW/cm ² on the plate surface at 35° C. for 4.5 minutes. The lenses are transferred to a large vial containing 70% (v/v) IPA and shaken for at least 12 hours and subsequently washed twice with DIW and twice with borate buffered storage solution. Finally, the lenses are sterilized by autoclaving at 121°C for about 30 minutes.

Example 11 (possible use)

The reactive monomer mixture is prepared by mixing the reactive components listed in Table 7. This composition is filtered through a 3 µm filter using a heated or unheated stainless steel or glass syringe, depending on the viscosity, and degassed by applying a vacuum (about 40 mmHg) at ambient temperature for about 45 minutes. Under an atmosphere of nitrogen gas and about 0.5 percent oxygen gas, 75 μl of the reaction mixture is dosed into an FC form made from Z or from a mixture of Z and TT in a ratio of 90:10 (w/w). Subsequently, BC made from PP or from a mixture of Z : PP 90 : 10 (w/w) is placed on the FC. Eight trays, each containing eight lens mold assemblies, are irradiated for 10 minutes at 65°C using a 435 nm LED having an intensity at the tray surface of 5 mW/cm ² . The light source is placed above the pallets. Working under yellow light, the lenses are mechanically separated from the molds using a hand press and placed individually in tissue capsules. Subsequently, capsules containing lenses are stored in amber colored plastic bottles until used in coating experiments ("Example 11 Substrates").

Table 7

Component Example 11,
% wt. HEMA 4.65 NVP 52.76 TRIS 19.97 TEGDMA 2.4 mPDMS 1000 19.86 Blue HEMA 0.02 Irgacure 819 0.34

In an inert atmosphere glove box, in a plastic plate (12 wells per plate), 2 ml of 25% (w/w) degassed DMA solution in PEG 400 is placed in each well, after which one lens is placed in each well from "Example 11. Substrates" concave side up and left to float freely. The well plate is covered with a transparent plastic sheet and irradiated with a 420 nm LED having an intensity of 10 mW/cm.² on the surface of the tablet at 35°C for 4.5 minutes. Before irradiation, the lenses are kept for about 1-5 minutes. The lenses are transferred to a large vial containing 70% (v/v) IPA and shaken for at least 12 hours and subsequently washed twice with DIW and twice with borate buffered storage solution. Finally, the lenses are sterilized by autoclaving at 121°C for about 30 minutes.

Example 12 (possible use)

Example 1 is repeated. The lenses are extracted with 70% IPA aqueous solution for at least 12 hours and then dried under vacuum until constant weight is reached.

In a glove box with an inert atmosphere, in a plastic plate (12 wells per plate), 2 ml of a 25% (w/w) degassed solution of 50 : 50 (mol/mol) HEMA : MPC in PEG 400 is placed in each well and subsequently, one extracted IPA and dried lens is placed in each well, concave side up, and allowed to float freely. The well plate is covered with a transparent plastic sheet and irradiated with a 420 nm LED having an intensity of 10 mW/cm ² on the plate surface at 35° C. for 4.5 minutes. The lenses are transferred to a large vial containing 70% (v/v) IPA for at least 12 hours (overnight) and subsequently washed twice with DIW and twice with borate buffered storage solution. Finally, the lenses are sterilized by autoclaving at 121°C for about 30 minutes.

Example 13 (possible use)

49.9 grams of α,ω-bis(2-hydroxyethoxypropyl)-polydimethylsiloxane (M _n =2000 daltons, Shin Etsu) is reacted with 11.1 grams of isophorone diisocyanate (IPDI) in 150 grams of dry methyl ethyl ketone (MEK) in the presence of 63 milligrams dibutyltin dilaurate at 40°C for 4.5 hours to form bis-IPDI terminated polydimethylsiloxane. An additional 63 milligrams of dibutyltin dilaurate is added to the reaction vessel. Subsequently, 164.8 grams of α,ω-bis(2-hydroxyethoxypropyl)-polydimethylsiloxane (M _n =3000 daltons, Shin Etsu) is mixed with 50 grams of dry MEK, and the resulting solution is added dropwise to a solution of bis-IPDI-terminated polydimethylsiloxane. The reactants are then allowed to react for 4.5 hours at 40°C, thus forming a bis-hydroxy terminated polydimethylsiloxane. An additional 63 milligrams of dibutyltin dilaurate is added and the MEK is removed by rotary evaporation under reduced pressure. The residue is reacted with 7.8 grams of isocyanatoethyl methacrylate (IEM) under an inert atmosphere until no isocyanate groups remain according to FTIR, thus forming a bis-methacrylate-terminated polymethylsiloxane (MA-PDMS-MA ).

Get the reaction monomer mixture having the following final composition: about 32-33% of the mass. MA-PDMS-MA, about 21-22% wt. TRIS-am, about 23-24% wt. DMA, about 1-2% of the mass. Irgacure 819, about 0.0-2.0 wt. surfactant such as DMPC and L-PEG, and about 0.01-0.1% of the mass. tint dye (for example, a 5% dispersion of copper phthalocyanine blue pigment in TRIS), and about 20-24% of the mass. 1-propanol as a diluent. For all reactive monomer mixtures, the sum of the weight percentages of the components is always 100%. The compositions may contain one or more free radical inhibitors.

The reaction monomer mixture is filtered through a 3 µm filter using a heated or unheated stainless steel or glass syringe, depending on the viscosity, and degassed by applying a vacuum (about 40 mmHg) at ambient temperature for about 45 minutes. Under an atmosphere of nitrogen gas and about 0.5 percent oxygen gas, 75 μl of the reaction mixture is dosed into a FC made from PP. BC made from PP was subsequently placed on FC. FC and BC molds can be made from PP, TT, Z or mixtures thereof. Ten trays, each containing eight lens mold assemblies, are irradiated for 10 minutes at 65°C using a 435 nm LED having an intensity at the tray surface of 5 mW/cm2. The light source is placed above the pallets. Working under yellow light, the lenses are mechanically separated from the molds using a hand press and placed individually in tissue capsules. Subsequently, capsules containing lenses are stored in amber plastic bottles until used in grafting or coating experiments ("Example 12 Substrates").

Working under yellow light, in a glove box with an inert atmosphere, in a plastic plate (12 wells per plate), 2 ml of a 25% (w/w) degassed solution of acrylic acid in PEG 400 was placed in each well and subsequently in each well. the well is placed one lens at a time ("Example 12. Substrates") with the concave side up and left to float freely. The well plate is covered with a transparent plastic sheet and irradiated with a 420 nm LED having an intensity of 10 mW/cm ² on the plate surface at 35° C. for about 5 minutes. The lenses are transferred to a large vial containing DIW and shaken for at least 12 hours and subsequently washed twice with fresh DIW (PAA coated lenses). The experiment was repeated with the addition of 1% (w/w) ethylene glycol dimethacrylate crosslinker in acrylic acid in PEG 400 to produce another batch of lenses (PAA-XL coated lenses). PAA stands for poly(acrylic acid). Before the next step, PAA and PAA-XL coated lenses can be equilibrated in borate buffered storage solution.

90 : 10 (mol/mol) poly(acrylamide-co-acrylic acid) (poly(AAM-co-AA), Mw=200,000 daltons, 90% solids, partial sodium salt) was purchased from Polysciences and used in the resulting form. Cumene polyamide ester (PAE) was purchased from Ashland (azetidinium content 0.46% as determined by, for example, nuclear magnetic resonance spectroscopy) as an aqueous solution and used as received. Preparing a saline coating solution in the package (IPC), having the following ingredients and concentrations: about 0.07% of the mass. poly(AAm-co-AA), about 0.15% wt. PAE (initial azetidinium millimolar equivalent of about 8.8 mmol) in phosphate buffered saline (PBS). PBS consists of about 0.044% of the mass. NaH ₂ PO ₄ -H ₂ O, about 0.388% of the mass. Na ₂ HPO ₄ -2H ₂ O and about 0.79% of the mass. NaCl, the final pH was adjusted to 7.2-7.4. Subsequently, the IPC brine is subjected to a preliminary heat treatment for about 4 hours at a temperature of about 70 °C. This heat pre-treatment allows the poly(AAM-co-AA) and PAE to incompletely react (ie retain some azetidinium groups) to form a water soluble branched material. After heat pretreatment, the hot IPC brine is filtered through a 0.22 micron PES membrane filter and allowed to cool to room temperature. Approximately 10 ppm hydrogen peroxide is added to the IPC saline solution to prevent bioburden growth, and the IPC saline solution is again filtered with a 0.22 micron PES membrane filter.

PAA-coated lenses or PAA-XL-coated lenses are individually placed in polypropylene blisters containing 0.3-0.5 ml of final IPC saline solution. After transferring the lens to the blister pack, an additional 0.3-0.5 ml of the final IPC saline solution is added to each blister. Subsequently, the blisters are sealed with foil and autoclaved for about 30 minutes at about 121°C, during which time the water-soluble branched material made from poly(AAm-co-AA) and PAE reacts with PAA on the lens surface, thus forming a cross-linked coating made of PAA, poly(AAm-co-AA) and PAE on the surface of the lens.

Claims (45)

1. An ophthalmic device formed by a method including: (a) providing a first reactive composition comprising: (i) a polymerization initiator which is capable, upon first activation, of forming two or more free radical groups, at least one of which may be further activated upon subsequent activation; (ii) one or more ethylenically unsaturated compounds; and (iii) a cross-linking agent; (b) subjecting the first reactive composition to a first activation step such that the first reactive composition polymerizes thereon to form a cross-linked substrate network containing a covalently bound, activated free radical polymerization initiator; (c) contacting the cross-linked substrate network with a grafting composition containing one or more ethylenically unsaturated compounds, wherein the contacting is carried out under such conditions that the grafting composition penetrates the cross-linked substrate network and is more concentrated on the surface transversely -crosslinked substrate network than in the core; and (d) activating a covalently bound, activated free radical polymerization initiator at the cross-linked substrate network such that the graft composition polymerizes at that location with the cross-linked substrate network. 2. The ophthalmic device of claim 1, wherein the grafting composition of step (c) contains a cross-linking agent. 3. An ophthalmic device according to claim 1, wherein the grafting composition of step (c) does not contain a cross-linking agent. 4. Ophthalmic device according to any one of paragraphs. 1-3, in which one or more ethylenically unsaturated compounds of step (a) contain one or more polymerizable groups independently selected from: (meth)acrylate, (meth)acrylamide, styryl, vinyl, N-vinyl lactam, N-vinylamide, simple O -vinyl ether, O-vinyl carbonate, O-vinyl carbamate, C _2-12 alkenyl, C _2-12 alkenylphenyl, C _2-12 alkenylnaphthyl and C _2-6 alkenylphenyl-C _1-6 alkyl. 5. Ophthalmic device according to any one of paragraphs. 1-4, in which one or more ethylenically unsaturated compounds of step (c) contain one or more polymerizable groups independently selected from: (meth)acrylate, (meth)acrylamide, styryl, vinyl, N-vinyl lactam, N-vinylamide, simple O -vinyl ether, O-vinyl carbonate, O-vinyl carbamate, C _2-12 alkenyl, C _2-12 alkenylphenyl, C _2-12 alkenylnaphthyl and C _2-6 alkenylphenyl-C _1-6 alkyl. 6. Ophthalmic device according to any one of paragraphs. 1-5, in which the polymerization initiator is bisacylphosphine oxide, bisacylphosphine oxide, diazo compound, diperoxide compound, azo-bis(monoacylphosphine oxide), azo-bis(monoacylphosphine oxide), peroxy-bis(monoacylphosphine oxide), peroxy-bis(monoacylphosphonoxide), azo-bis (alpha-hydroxyketone), peroxy-bis(alpha-hydroxyketone), azo-bis(1,2-diketone), peroxy-bis(1,2-diketone), germanium-based compound, tert-butyl-7-methyl- 7-(tert-butylazo)peroxyoctanoate or combinations thereof. 7. Ophthalmic device according to any one of paragraphs. 1-6, in which the polymerization initiator is a bisacylphosphine oxide or bis(acyl)phosphanoxide. 8. Ophthalmic device according to any one of paragraphs. 1-7, which is in the form of a hydrogel and in which the first reactive composition contains one or more silicone-containing components, and the composition for grafting contains one or more hydrophilic reactive components. 9. Ophthalmic device according to any one of paragraphs. 1-7, which is in the form of a hydrogel and in which the first reactive composition contains one or more hydrophilic reactive components, and the grafting composition contains one or more silicone-containing components. 10. Ophthalmic device according to any one of paragraphs. 1-9, in which the first reactive composition, the grafting composition, or both the first reactive composition and the grafting composition contain one or more additives selected from UV absorbers, photochromic compounds, pharmaceutical compounds, nutraceutical compounds, antimicrobial compounds, reactive coloring agents, pigments, copolymerizable dyes, non-polymerizable dyes, release agents, wetting agents and release agents. 11. Ophthalmic device according to any one of paragraphs. 1-10 selected from the group consisting of a contact lens, an intraocular lens, a punctal obturator, and an ophthalmic insert. 12. An ophthalmic device made from a reaction product of a composition containing: (i) a cross-linked substrate network containing covalently linked activated free radical initiators; and (ii) a grafting composition containing one or more ethylenically unsaturated compounds, moreover, the concentration of the composition for grafting is greater on the surface of the cross-linked substrate network than in its core. 13. The ophthalmic device of claim 12, wherein the grafting composition further comprises a cross-linking agent. 14. Ophthalmic device according to any one of paragraphs. 12, 13, in which the cross-linked substrate network is the reaction product of a first reactive composition containing: (i) a polymerization initiator that is capable, upon first activation, of forming two or more free radical groups, at least one of which may additionally be activated upon subsequent activation; (ii) one or more ethylenically unsaturated compounds; and (iii) a cross-linking agent. 15. The ophthalmic device according to claim 14, wherein the polymerization initiator is a bisacylphosphine oxide, a bisacylphosphine oxide, a diazo compound, a diperoxide compound, azo-bis(monoacylphosphine oxide), azo-bis(monoacylphosphine oxide), peroxy-bis(monoacylphosphine oxide), peroxy-bis(monoacylphosphonoxide). ), azo-bis(alpha-hydroxyketone), peroxy-bis(alpha-hydroxyketone), azo-bis(1,2-diketone), peroxy-bis(1,2-diketone), germanium-based compound, tert-butyl -7-methyl-7-(tert-butylazo)peroxyoctanoate; or combinations thereof. 16. The ophthalmic device of claim 14 wherein the polymerization initiator is bisacylphosphine oxide or bis(acyl)phosphane oxide. 17. Ophthalmic device according to any one of paragraphs. 12-16, wherein one or more of the ethylenically unsaturated compounds in the grafting composition and the first reactive composition contain polymerizable groups independently selected from: (meth)acrylate, (meth)acrylamide, styryl, vinyl, N-vinyl lactam, N-vinylamide, simple O-vinyl ether, O-vinyl carbonate, O-vinyl carbamate, C _2-12 alkenyl, C _2-12 alkenylphenyl, C _2-12 alkenylnaphthyl, and C _2-6 alkenylphenyl-C _1-6 alkyl. 18. Ophthalmic device according to any one of paragraphs. 12-17, in which the cross-linked substrate network is formed from one or more silicone-containing components, and the grafting composition contains hydrophilic reactive components. 19. Ophthalmic device according to any one of paragraphs. 12-17, in which the cross-linked substrate network is formed from one or more hydrophilic reactive components, and the grafting composition contains one or more silicone-containing components. 20. Ophthalmic device according to any one of paragraphs. 12-17, in which the cross-linked substrate network is formed from one or more hydrophilic reactive components, and the graft composition contains hydrophilic reactive components. 21. Ophthalmic device according to any one of paragraphs. 12-17, in which the cross-linked substrate network is formed from one or more silicone-containing components, and the grafting composition contains one or more silicone-containing components. 22. Ophthalmic device according to any one of paragraphs. 12-21, in which the cross-linked substrate network, the grafting composition, or both the cross-linked substrate network and the grafting composition contain one or more additives selected from UV absorbers, photochromic compounds, pharmaceutical compounds, nutraceutical compounds, antimicrobial compounds, coloring agents, pigments, dyes, dyes, release agents and wetting agents. 23. A method for obtaining an ophthalmic device, including: (a) providing a first reactive composition comprising: (i) a polymerization initiator that is capable, upon first activation, of forming two or more free radical groups, at least one of which may be further activated upon subsequent activation; (ii) one or more ethylenically unsaturated compounds; and (iii) a cross-linking agent; (b) subjecting the first reactive composition to a first activation step such that the first reactive composition polymerizes thereon to form a cross-linked substrate network containing a covalently bound, activated free radical polymerization initiator; (c) contacting the cross-linked substrate network with a grafting composition containing one or more ethylenically unsaturated compounds, wherein the contacting is carried out under such conditions that the grafting composition penetrates the cross-linked substrate network and is more concentrated on the surface transversely -crosslinked substrate network than in the core; and (d) activating a covalently bound, activated free radical initiator at the cross-linked substrate network such that the graft composition polymerizes at that location with the cross-linked substrate network to form an ophthalmic device. 24. The method of claim 23, wherein the grafting composition of step (c) contains a cross-linking agent. 25. The method of claim 23 wherein the grafting composition of step (c) does not contain a crosslinker. 26. The method according to any one of paragraphs. 23-25, in which one or more ethylenically unsaturated compounds of step (c) contain one or more polymerizable groups independently selected from: (meth)acrylate, (meth)acrylamide, styryl, vinyl, N-vinyl lactam, N-vinylamide, simple O -vinyl ether, O-vinyl carbonate, O-vinyl carbamate, C _2-12 alkenyl, C _2-12 alkenylphenyl, C _2-12 alkenylnaphthyl and C _2-6 alkenylphenyl-C _1-6 alkyl. 27. The method according to any one of paragraphs. 23-26, in which one or more ethylenically unsaturated compounds of step (c) contain one or more polymerizable groups independently selected from: (meth)acrylate, (meth)acrylamide, styryl, vinyl, N-vinyl lactam, N-vinylamide, simple O -vinyl ether, O-vinyl carbonate, O-vinyl carbamate, C _2-12 alkenyl, C _2-12 alkenylphenyl, C _2-12 alkenylnaphthyl and C _2-6 alkenylphenyl-C _1-6 alkyl. 28. The method according to any one of paragraphs. 23-27, in which the polymerization initiator is bisacylphosphine oxide, bisacylphosphine oxide, diazo compound, diperoxide compound, azo-bis(monoacylphosphine oxide), azo-bis(monoacylphosphine oxide), peroxy-bis(monoacylphosphine oxide), peroxy-bis(monoacylphosphonoxide), azo-bis (alpha-hydroxy ketone), peroxy-bis (alpha-hydroxy ketone), azo-bis(1,2-diketone), peroxy-bis(1,2-diketone), germanium-based compound, tert-butyl-7-methyl- 7-(tert-butylazo)peroxyoctanoate or combinations thereof. 29. The method according to any one of paragraphs. 23-28, wherein the polymerization initiator is a bisacylphosphine oxide or a bis(acyl)phosphanoxide. 30. The method according to any one of paragraphs. 23-29, which is in the form of a hydrogel, and wherein the first reactive composition contains one or more silicone-containing components, and the grafting composition contains one or more hydrophilic reactive components. 31. The method according to any one of paragraphs. 23-29, which is in the form of a hydrogel and wherein the first reactive composition contains one or more hydrophilic reactive components and the grafting composition contains one or more silicone-containing components. 32. The method according to any one of paragraphs. 23-31, in which the first reactive composition, the grafting composition, or both the first reactive composition and the grafting composition contain one or more additives selected from UV absorbers, photochromic compounds, pharmaceutical compounds, nutraceutical compounds, antimicrobial compounds, reactive coloring agents agents, pigments, copolymerizable dyes, non-polymerizable dyes, release agents, wetting agents and release agents. 33. Ophthalmic device according to any one of paragraphs. 1-11, wherein the method further comprises: after step (d) contacting the cross-linked substrate network with a second graft composition containing one or more ethylenically unsaturated compounds and activating the residual covalently bound, activated free radical polymerization initiator in the cross-linked substrate network such that the second graft composition polymerizes at that location with the cross-linked substrate network. 34. Ophthalmic device according to any one of paragraphs. 1-11, wherein the grafting composition of step (c) is contained in a lens storage solution and step (d) is carried out in a lens package.