200824881 九、發明說明： 【發明所屬之技術領域】- 本發明關於用以成型一眼科鏡片的模具。更特定δ 之，本發明關於利用橫跨二或更多個模具部件施加之一靜 5 電電荷差塑造一眼科鏡片使得製程中產生較少孔洞缺陷的 裝置及方法。 【先前技術】 眾所周知隱形眼鏡可用來改善視力。各式各樣的隱形 10 眼鏡已在市面上販售多年。早期的隱形眼鏡設計係用硬質 材料塑造。儘管此等鏡片當今仍在一些應用中使用’其因 舒適度不佳及相對較低透氧性而不適合用於所有患者。此 領域中之較新近發展產生以水凝膠為基礎的軟式隱形眼 鏡。 15 水凝膠隱形眼鏡在今天非常流行。此等鏡片戴起來通 常比硬質材料製成之隱形眼鏡舒適許多。軟式隱形眼鏡可 藉由在一多部件模具内成型一鏡片的方式製造，其中組合 在一起的多個部件形成一與期望最終鏡片—致之形貌。 眼科鏡片通常藉由洗鑄成变方式製造，其中將一單體 20 材料沈積於一界定在相對模具部件之光學表面之間的模八 内。用以將水凝膠塑造成一有用物件（譬如眼科鏡片）的 多部件模具舉例來說可包含··/第一模具部件，其具備一 對應於眼科鏡片背曲面的凸形部分；及一第；模具部件， 其具備一對應於眼科鏡片前曲面的凹形部分。應理解到除 5 200824881 #文中另有明確說明，第一模具部件亦可包含前曲面模具 部件，其中第二模具部件因此會包括一背曲面模具部件。 要利用此等模具部件製備鏡片時，將一未固化水凝膠 鏡片調配物放在模具部分之凹面與凸面之間且隨後使其固 5 10 15 化。水凝膠鏡片調配物舉例來説可藉由暴露於熱和光任一 者或二者而固化。固化的水凝膠依據該等模具部分之尺寸 形成一鏡片。 在固化之後’傳統實務方式要求分離該等模具部分， 、鏡片仍黏附於该等模具部分之一者。一脫模程序使鏡片 脫離留下的模具部件。 又此領域中之新發展已得到經聚合物塗布以提升鏡 t適度之水凝膠和聚矽氧水凝膠製隱形眼鏡。通常鏡片 的=由用—聚合物處理已固化鏡片的方式接受塗布。新近 一物塗布鏡片係藉由下述方式製作：用一聚合物塗本 =件拉具之表面，將一未固化調配物加到已經塗布的 =具，使鏡片固化，然後從模具釋出已固化的鏡片， 塗布二已ϋ化鏡片之表面被原輕附於模具表面之聚合物 頃已知有些模具材料會對模具部件賦予可能合乎期望 些特性譬如模數品f，而其他模具材料可能提供模異 4所需要之某些特性譬如表面特質。近來已知對於前曲 面松具部件和背曲面模具部件改變為使用不同模具材料藉 以促成更有效之脫模作業。但頃亦已知曉迥異的材料會導 致由此等模具總成成型之鏡片中的孔洞增加。 6 200824881 一種解決孔洞缺陷增加的方法包含放慢將一鏡片構成 混合物沈積於一模穴内的潤濕程序。但此方法並非永遠有 效，且即便有效也不為人喜用，因為會使生產時間拉長。 因此，最好提出促成在不同模具部件中具備來自不同 5 模具材料之期望特性的模具總成之使用同時仍維持最佳潤 濕循環時間及減少鏡片孔洞發生的裝置及方法。 【發明内容】 據此，本發明提出用以減少鏡片製程中之鏡片孔洞發 10 生的方法及裝置。 依據本發明，可形成多個模具總成，每一模具總成包 含一第一模具部件和一第二模具部件的匹配組合。在每一 組第一模具部件和第二模具部件之間賦予一靜電電荷差， 且將一反應混合物投入該第一模具部件内。使每一組之每 15 —第二模具部件耦接於每一第一模具部件以於其間形成一 模穴。該反應混合物因此成型為該模穴之形狀。使該反應 混合物暴露於光化輻射藉以形成多個眼科鏡片。檢查已成 型的多個鏡片之孔洞缺陷以判斷已成型的多個鏡片當中孔 洞缺陷發生率是否低於一閾值。 20 可用來施行本發明各觀點之裝置舉例來說可包含一具 備一表面能之模具總成，該表面能可為材料是否會黏附於 模具之一表面的指標。該模具總成可包含一第一模具部件 和一第二模具部件，其中每一模具部件包含一鏡片成型表 面。一鏡片可藉由下述方式模製於該等模具部件之間：將 7 5 10 15 20 200824881 第一綱件之㈣型表面與該 固化。-靜電充電=:之，，且使該鏡片構成材料 成型表面*知作以在_—模具部件之鏡片 電電荷差。、兮笛具部件之鏡片成型表面之間賦予一靜 電荷差可A”具部件與該第二模具部件之間的靜電 了為在一約30 kV之範圍内。 【實施方式】 鏡片關於經由二或更多個模具部件模塑眼科 電荷差橫跨該等模具部件的靜電 此實魅φ Γγ μ表面能。特定言之在- 种’本發明關於兩模具部料如—底 = 型；二：：面模具部件的使用’其中該底曲面之一鏡；； 缺陷:少。相對於該前曲面為正的靜電電荷導致鏡片孔洞 依據本發明，至少射出成 «之前經靜電處理藉以改變用於型部分在組 之原料之表面特性。在各實:^柄具部件形成程序中 可為正或負絕對充電）或藉由在二絕對充電（其 電差的方式運用靜電充電。兩拉具部件之間賦予一靜 在一些實施例中，可施加+或〜 現鏡片孔洞缺陷減小。一此較佳• 靜％電荷以實 具部件的情況包含〇kv至一如使用聚丙稀模 使用聚丙埽模具部件的情況， 的較佳^圍。譬如在 取侄粑圍包含一模具總成 8 200824881 所含模具部件之間_ 電荷差。 ·Ζ kV至+或一1.5 kV靜電 橫跨模具部件恭 - 5 10 15 20 率從超過5G%之_ ΰ七包私何差的使用已將鏡片孔洞發生 洞缺陷的發生率。：一孔陷降到少柃10%之鏡片有孔 %之鏡片孔洞缺陷。一些貫施例中’靜電電荷差造成低於5 在另一觀點中，一棒跨一二 模具部件之靜雷I 、 m 拉具部件和一背曲面 的潤濕速度μ施加促進單體沈積於—模具部件期間 各貝施例可包含一在射出成型 的靜電電荷，授予靜雷+ 1 %由取終總成杈予 裝之前（詳見下文）。 場合係在模具正要組 在鏡、'孔洞缺陷，，意指眼科鏡片中之缺陷， 在鏡片表面中包括鏡片材料之空洞。 戍目jtr明書中，、、鏡片"或 '、眼科鏡片"意指放在眼上 的任何眼科11件。此等ϋ件可提供光學矯正效果或 ϋ :、、、=飾性。舉例來說，鏡片一辭可指隱形眼鏡 、眼内 ^、、$蓋鏡片、眼球嵌件、光學嵌件或其他類似器件， 透過此等為件使視力得到矯正或改善，或是藉由此等器件 使眼睛外觀強調化妝效果（譬如虹膜顏色）而無礙視力。 旧入在本說明書中，、、鏡片構成混合物//(有時亦稱、、反應 此合物）意指可被固化形成眼科鏡片的單體或預聚物材 9 200824881 料。各實施例可包含具有一或多種下列添加物的混合物： uv阻隔劑，染色劑，光引發劑_或催化劑，及吾人可能希望 諸如隱形眼鏡或眼内鏡片之眼科鏡片中擁有的其他添加 物。鏡片構成混合物將在下文更進一步說明。 5 在本說明書中，''模具部件〃意指可用來從未固化調配 物形成鏡片的塑性、剛性或半剛性物件。 在本說明書中，''未固化〃意指反應混合物（有時稱''鏡 片調配物〃）在最終固化形成鏡片之前的物理狀態。有些反 應混合物含有只會固化一次之單體的混合物。其他反應混 10 合物含有單體、部分固化單體、大分子單體及其他組份。 在本說明書中，〜鏡片成型表面〃意指用來模塑鏡片的 表面103-104。在一些實施例中，任何此等鏡片103-104可 具有光學品質的表面拋光，這代表其夠光滑且被形成為使 得因與此模塑表面接觸之鏡片構成材料之聚合化作用而塑 15 造的鏡片表面是光學可接受的。又，在一些實施例中，鏡 片成型表面103-104得具有對鏡片表面賦予期望光學特性 所需要的幾何形狀，此等光學特性非侷限性包含球面、非 球面和柱面光焦度，波前像差矯正，角膜形貌矯正和類似 特性以及以上之任何組合。 20 帶靜電的模具 在可用以從未固化調配物形成鏡片之塑膠模具的形成 當中，較佳模具包含二個部件，其中前曲面或背曲面部件 係在造模工具中形成，此造模工具在用以塑造塑膠模具部 10 200824881 件之炼融材料注入之前已被冷卻到該造模工具周遭之溫度 或更低溫度。 今參照圖1，其例示一用於眼科鏡片製造之範例模具部 件101-102及靜電充電器件109-110的示意圖。模具總成可 包含一具有一模穴1〇5的模型100,鏡片構成混合物可施配 於該模穴内致使在該鏡片構成混合物反應或固化之後，製 成一期望形狀的眼科鏡片1〇8。本發明之模具和模具總成 1〇〇係由二或更多個、、模具部件〃或\、模件〃 1〇1-1〇2組成。 至少一模具部件101-102被設計成以其表面104-105之 至少一部分與鏡片構成混合物接觸致使在該鏡片構成混合 物反應或固化之後，表面104-105對與其接觸之鏡片部分 (鏡片成型表面//)提供一期望形狀和樣式。至少另一模 具部件101-102亦如此。與反應混合物發生接觸之凹面1〇4 部分具有欲在模具總成1〇〇内製造之眼科鏡片之前曲面的 曲率，此部分夠光滑且被形成為致使因與凹面1〇4接觸之 反應混合物之聚合作用而形成的眼科鏡片之表面是光學可 接受的。 相似地，背曲面模具部件101有一凸面1〇5，該凸面與 鏡片構成混合物接觸且具有欲在模具總成100内製造之眼 科鏡片之背曲面的曲率。凸面105夠光滑且被形成為致使 因與背面105接觸之鏡片構成混合物之反應或固化作用而 形成的眼科鏡片之表面是光學可接受的。據此，前曲面模 具部件102之内凹面104界定眼科鏡片之外表面，而背模 件101之外凸面105界定眼科鏡片之内表面。 、 11 200824881 因模=Γ101·102可被帶到一起或、接致使-模穴 1〇m 102合併而形成，且鏡片和旱以在楔穴 片形成101，2之合併較佳為暫時性。在鏡 件1GMG2可再次分離以移出已成型的 $開。Θ不背曲面模具部件101從前曲面模具部件ι〇2 10 15 20 依據本發明，靜電電荷1G3A_咖施加於前曲面模具 和背曲面模具部件剛之-者或二者。靜電電荷 牛歹]^況可為經由緊鄰相應一或多個模具部件1〇1_1〇2放 ^之或夕個靜電棒109-110賦予。在一些較佳實施例中， 靜電棒被定位為緊鄰凸形鏡片成型表面105和凹形鏡片成 型、表Γ 1〇4之一者或二者。儘管靜電電荷在圖中示為103Α ^或103Β、、一”，熟習此技藝者會理解到這些表示僅 為範例，實施例可包含依一正或負方向之一差，或具備一 電荷為正或負的電壓差。 在一些較佳實施例中，模具材料可包含以200824881 IX. Description of the invention: [Technical field to which the invention pertains] - The present invention relates to a mold for molding an ophthalmic lens. More specifically, the present invention relates to an apparatus and method for shaping an ophthalmic lens by applying a static electric charge difference across two or more mold parts to produce fewer void defects in the process. [Prior Art] It is well known that contact lenses can be used to improve vision. A wide variety of invisible 10 glasses have been on the market for many years. Early contact lens designs were shaped with hard materials. Although these lenses are still used today in some applications, they are not suitable for use in all patients due to poor comfort and relatively low oxygen permeability. Newer developments in this field have resulted in hydrogel-based soft contact lenses. 15 Hydrogel contact lenses are very popular today. These lenses are generally much more comfortable to wear than hard materials made of hard materials. Soft contact lenses can be made by molding a lens in a multi-part mold wherein the plurality of components combined form a topography with the desired final lens. Ophthalmic lenses are typically manufactured by a die-casting process in which a monomer 20 material is deposited in a mold 8 defined between the optical surfaces of the opposing mold parts. The multi-part mold for shaping the hydrogel into a useful article (such as an ophthalmic lens) may, for example, comprise a first mold member having a convex portion corresponding to the back surface of the ophthalmic lens; and a first; A mold part having a concave portion corresponding to a front curve of the ophthalmic lens. It should be understood that the first mold part may also include a front curve mold part, wherein the second mold part will thus include a back curved mold part, except as otherwise explicitly stated in the document. To prepare the lens using such mold parts, an uncured hydrogel lens formulation is placed between the concave and convex surfaces of the mold portion and subsequently solidified. Hydrogel lens formulations can be cured, for example, by exposure to either or both heat and light. The cured hydrogel forms a lens depending on the size of the mold portions. After curing, the conventional practice requires separation of the mold portions, and the lens remains adhered to one of the mold portions. A demolding process disengages the lens from the remaining mold parts. Further developments in this field have resulted in contact lenses that have been coated with a polymer to enhance the proper morphology of hydrogels and polyoxyhydrogels. Typically the lens = is coated by treating the cured lens with a polymer. A recent coated lens is made by coating the surface of the device with a polymer, applying an uncured formulation to the already coated yoke, curing the lens, and then releasing it from the mold. Cured lenses, polymers coated with the surface of the two deuterated lenses that are lightly attached to the surface of the mold are known to have some mold materials that impart desirable properties to the mold parts, such as modulus, while other mold materials may provide Some of the characteristics required for Modular 4 are such as surface traits. It has recently been known to change the use of different mold materials for the front curved loft component and the back curved mold component to facilitate more efficient demolding operations. However, it has also been known that the weird material will result in an increase in the number of holes in the lens formed by such a mold assembly. 6 200824881 A method of addressing the increase in void defects involves slowing down a wetting procedure for depositing a lens-forming mixture into a cavity. However, this method is not always effective, and even if it is effective, it is not popular, because it will lengthen the production time. Accordingly, it is desirable to provide means and methods that facilitate the use of mold assemblies having the desired characteristics of different mold materials in different mold parts while still maintaining optimum wet cycle time and reducing lens hole occurrence. SUMMARY OF THE INVENTION Accordingly, the present invention is directed to a method and apparatus for reducing the occurrence of lens holes in a lens manufacturing process. In accordance with the present invention, a plurality of mold assemblies can be formed, each mold assembly comprising a mating combination of a first mold part and a second mold part. An electrostatic charge difference is imparted between each set of first mold part and second mold part, and a reaction mixture is introduced into the first mold part. Each of the 15 - second mold members of each set is coupled to each of the first mold members to form a cavity therebetween. The reaction mixture is thus shaped into the shape of the cavity. The reaction mixture is exposed to actinic radiation to form a plurality of ophthalmic lenses. The hole defects of the plurality of lenses that have been formed are checked to determine whether the incidence of hole defects among the plurality of lenses that have been formed is below a threshold. 20 Apparatus which can be used to carry out the various aspects of the present invention, for example, can include a mold assembly having a surface energy which can be an indicator of whether the material will adhere to one of the surfaces of the mold. The mold assembly can include a first mold part and a second mold part, wherein each mold part includes a lens forming surface. A lens can be molded between the mold parts by: solidifying the surface of the (4) type of the first piece of the 7 5 10 15 20 200824881. - Electrostatic charging =:, and the lens constituting material forming surface * is known as the difference in electric charge of the lens of the _-mold part. And a static charge difference between the lens forming surfaces of the squid parts is A. The static electricity between the component and the second mold part is in a range of about 30 kV. [Embodiment] Or more than one mold part molding ophthalmic charge difference across the electrostatic properties of the mold parts, the specific surface of the surface energy. Specifically, the present invention relates to two mold parts such as - bottom = type; : use of a surface mold part 'where one of the bottom curved surfaces is mirrored;; defect: less. Positive electrostatic charge relative to the front curved surface causes the lens hole to be in accordance with the invention, at least injected into a «previously electrostatically processed to change the type used Part of the surface properties of the raw materials in the group. In each: the handle can be positive or negative, or can be charged by electrostatic charging. In some embodiments, it is possible to apply + or ~ to reduce the lens hole defect. It is preferable that the static % charge contains 〇kv in the case of a component, and the polypropylene die is used as in the case of using a polypropylene die. In the case of parts, it is better to do. For example, in the case of a mold containing a mold assembly 8 200824881, the mold parts contained _ charge difference. Ζ kV to + or a 1.5 kV static across the mold parts Christine - 5 10 15 20 rate from more than 5G% _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ In the example, 'the electrostatic charge difference causes less than 5. In another point of view, the wetting speed of a static rod I, m pull member and a back surface of a rod span of one or two mold parts is applied to promote monomer deposition on - During the mold part, each shell embodiment may include an electrostatic charge generated by injection molding, and the static mine + 1% is given before the final assembly is loaded (see below). The occasion is in the mold to be set in the mirror, 'hole Defect, meaning a defect in an ophthalmic lens, including a cavity of the lens material in the lens surface. In the eyepiece jtr, ", lens" or ', ophthalmic lens' means any ophthalmology placed on the eye 11 These pieces can provide optical correction or ϋ :, , , = For example, a lens term may refer to a contact lens, an intraocular lens, an eye lens, an eye insert, an optical insert, or the like, through which the vision is corrected or improved, or borrowed. Such devices allow the appearance of the eye to emphasize the cosmetic effect (such as iris color) without obstructing the vision. In the present specification, the lens constitutes a mixture // (sometimes called, reacts to the compound) means that it can be A monomer or prepolymer material that cures to form an ophthalmic lens. 9 200824881. Each embodiment may comprise a mixture of one or more of the following additives: a uv barrier, a dye, a photoinitiator or a catalyst, and may be desired by us. Other additives found in ophthalmic lenses for contact lenses or intraocular lenses. The lens composition mixture will be further explained below. 5 In this specification, ''mold component' means a plastic, rigid or semi-rigid article that can be used to form a lens from an uncured formulation. In the present specification, ''uncured 〃 means the physical state of the reaction mixture (sometimes referred to as ''mirror formulation 〃) before final curing to form a lens. Some reaction mixtures contain a mixture of monomers that will only cure once. Other reaction mixtures contain monomers, partially cured monomers, macromonomers, and other components. In the present specification, the lens forming surface 〃 means the surface 103-104 used to mold the lens. In some embodiments, any of these lenses 103-104 may have an optical quality surface finish, which means that it is smooth enough and is formed such that it is plasticized by the polymerization of the lens constituent materials in contact with the molding surface. The lens surface is optically acceptable. Again, in some embodiments, the lens forming surfaces 103-104 are provided with the geometry required to impart desired optical properties to the lens surface, such optical features being non-limiting including spherical, aspherical, and cylindrical powers, wavefronts Aberration correction, corneal topography and similar properties, and any combination of the above. 20 electrostatically charged molds In the formation of plastic molds that can be used to form lenses from uncured formulations, the preferred mold comprises two parts, wherein the front curve or back curve part is formed in a molding tool, the molding tool is The smelting material used to shape the plastic mold part 10 200824881 has been cooled to a temperature around the molding tool or lower. Referring now to Figure 1, a schematic diagram of an exemplary mold component 101-102 and an electrostatic charging device 109-110 for ophthalmic lens manufacture is illustrated. The mold assembly can include a mold 100 having a cavity 1 〇 5 into which a lens constituting mixture can be applied to cause an ophthalmic lens 1 〇 8 of a desired shape after the lens constituting mixture reacts or solidifies. The mold and mold assembly 1 of the present invention is composed of two or more, mold parts \ or \, modules 〃 1〇1-1〇2. At least one of the mold parts 101-102 is designed to contact the lens forming mixture with at least a portion of its surfaces 104-105 such that after the lens forming mixture reacts or solidifies, the surface 104-105 is in contact with the lens portion (lens forming surface / /) Provide a desired shape and style. The same is true of at least one other mold part 101-102. The portion of the concavity 1〇4 that is in contact with the reaction mixture has the curvature of the curved surface before the ophthalmic lens to be fabricated in the mold assembly, which is smooth enough and is formed to cause a reaction mixture in contact with the concave surface 〇4. The surface of the ophthalmic lens formed by polymerization is optically acceptable. Similarly, the back curve mold part 101 has a convex surface 〇5 that is in contact with the lens forming mixture and has the curvature of the back surface of the ophthalmic lens to be fabricated in the mold assembly 100. The convex surface 105 is smooth enough and is formed such that the surface of the ophthalmic lens formed by the reaction or solidification of the lens forming the mixture with the back surface 105 is optically acceptable. Accordingly, the concave surface 104 of the front curve mold member 102 defines the outer surface of the ophthalmic lens, and the outer convex surface 105 of the back mold 101 defines the inner surface of the ophthalmic lens. 11 200824881 The combination of the molds = Γ 101 · 102 can be brought together or the mold holes 1 〇 m 102 are combined, and the combination of the lens and the drought to form the wedge formation 101, 2 is preferably temporary. The mirror 1GMG2 can be separated again to remove the formed $ open. According to the present invention, the electrostatic charge 1G3A_coffee is applied to either the front curve mold and the back curve mold member. The electrostatic charge can be imparted via an electrostatic bar 109-110 placed immediately adjacent to the corresponding one or more mold parts 1〇1_1〇2. In some preferred embodiments, the static bar is positioned proximate to the convex lens forming surface 105 and the concave lens forming, one of the gauges 〇4 or both. Although the electrostatic charge is shown as 103 Α ^ or 103 Β , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , Or a negative voltage difference. In some preferred embodiments, the mold material may comprise
ExxonMobil PP9544MED®聚丙烯（9544 )用作底曲面及以n〇vaExxonMobil PP9544MED® Polypropylene (9544) is used as the bottom surface and is used as n〇va
Chemicals PolyStyrene VEREX 13〇〇⑧與硬脂酸鋅添加物化 合用作前曲面。 亦可使用替代材料譬如Zeon Chemical Corporation出 品之Zeonor和Zeonex與不同混合比例聚丙烯混合物類， 亦可使用聚烯fe類、環稀烴類及環稀烴共聚物類，在一些 實施例中包含聚烯烴類和C〇c類與添加物化合。在一些特 定實施例中’實例非侷限性包含·· PP9544與聚苯乙烯，55 12 200824881 %Zeonor與45%聚丙烯或聚苯乙烯，75%Zeonor與25%聚 丙烯或聚苯乙烯，25%Zeonor與75%聚丙烯或聚苯乙烯， 10%Zeonor與90%聚丙烯或聚苯乙烯，90%Zeonor與10 %聚丙烯或聚苯乙烯，50%Zeonor與50%聚丙烯或聚苯乙 5 烯，及ExxonMobil PP 1654 E暨上列比例。 這些混合樹脂可利用不同化合方法獲得，其中包含手 混、單螺桿化合、雙螺桿及/或多螺桿化合。 較佳實施例亦可包含下列物之一或多者：COC類、脂 環共聚物及聚丙烯當作主要模具部件材料。又，在一些實 10 施例中，本發明之模具可含有促進模具成型表面分離、減 低已固化鏡片與模塑表面之黏著力或兩種效果兼具的添加 物。舉例來說，可在使聚合物固化形成模具之前將添加物 譬如硬脂酸之金屬鹽或銨鹽類、醯胺蠟類、聚乙烯或聚丙 烯蠟類、有機磷酸酯類、甘油酯類或醇酯類添加於脂環共 15 聚物。此等添加物之實例非侷限性包含：Dow Siloxane MB50-001 或 321(聚矽氧分散體），Nurcrel 535 & 932(乙 烯-甲基丙烯酸共聚樹脂登錄編號25053-53-6)，Erucamide (脂肪酸醯胺登錄編號112-84-5)，Oleamide (脂肪酸醯胺 登錄編號 301-02-0)，Mica (登錄編號 12001-26-2)，Atmer 20 (脂肪烷基二乙醇胺登錄編號107043-84-5)，Pluronic (聚 氧丙烯-聚氧乙烯嵌段共聚物登錄編號106392-12-5 )， Tetronic (烷氧基化胺 110617-70-4 )，Flura (登錄編號 7681-49-4)，硬脂酸|弓，硬脂酸鋅，Super-Floss抗結塊劑（滑 溜/抗結塊劑登錄編號61790-53-2)，Zeospheres抗結塊劑 13 200824881 (滑溜/抗結塊劑）；Ampacet 40604 (脂肪酸醯胺）， Kemamide (脂肪酸醯胺），Lico_wax脂肪酸醯胺，Hypermer B246SF，XNAP，聚乙烯單月桂酸乙二醇酯（抗靜電）環 氧化大豆沙拉油，滑石（水合矽酸鎂），碳酸鈣，二十二酸， 異戊四醇四硬脂酸|旨，珑珀酸，epolene E43-Wax，甲基纖 維素，cocamide (抗結塊劑登錄編號61789-19-3)，聚乙稀 吡咯烷酮（ 360,000 MW)。較佳添加物為聚乙烯吡咯燒g同、 硬月曰酸辞和单硬脂酸甘油自旨’其中以聚合物總重為基準的 添加物重量百分率是約0·05至約1〇.〇重量百分率，較佳約 〇·〇5至約3.0重量百分率，最佳是約2.0重量百分率。 在一些實施例中，除了添加物，可藉由對鏡片成型表 面施加界面活性劑的方式促進鏡片從鏡片成型表面分離。 適合的界面活性劑實例包含Tween界面活性劑，特別是如 美國專利第5,837,314號所述之Tween80(該專利之内容以 引用的方式併入本文中）以及Span 80。 再者，在一些實施例中，本發明之模具可含有其他聚 合物譬如聚丙烯，聚乙烯，聚苯乙烯，聚甲基丙烯酸曱酯， 在主鏈中含有脂環半部（m〇iety )的改性聚烯烴類以及環聚Chemicals PolyStyrene VEREX 13〇〇8 is combined with a zinc stearate additive for use as a front curve. Alternative materials such as Zeonor and Zeonex from Zeon Chemical Corporation and polypropylene blends of different mixing ratios may also be used, and polyene fe, cycloaliphatic and cycloaliphatic copolymers may also be used, in some embodiments comprising poly The olefins and C〇c are combined with the additives. In some specific embodiments 'example non-limiting includes PP9544 with polystyrene, 55 12 200824881 % Zeonor with 45% polypropylene or polystyrene, 75% Zeonor with 25% polypropylene or polystyrene, 25% Zeonor with 75% polypropylene or polystyrene, 10% Zeonor with 90% polypropylene or polystyrene, 90% Zeonor with 10% polypropylene or polystyrene, 50% Zeonor with 50% polypropylene or polystyrene 5 Aene, and ExxonMobil PP 1654 E and the above ratio. These mixed resins can be obtained by various chemical methods including hand blending, single screw compounding, twin screwing and/or multi-screw combining. The preferred embodiment may also comprise one or more of the following: COCs, alicyclic copolymers and polypropylene as the primary mold component material. Further, in some embodiments, the mold of the present invention may contain an additive which promotes separation of the mold forming surface, reduces the adhesion of the cured lens to the molding surface, or both. For example, additives such as metal or ammonium salts of stearic acid, guanamine waxes, polyethylene or polypropylene waxes, organophosphates, glycerides or the like may be added prior to curing the polymer to form a mold. Alcohol esters are added to the alicyclic co-polymer. Examples of such additives are non-limiting include: Dow Siloxane MB50-001 or 321 (polyoxyl dispersion), Nurcrel 535 & 932 (ethylene-methacrylic copolymer resin registration number 25053-53-6), Erucamide ( Fatty acid guanamine registration number 112-84-5), Oleamide (fatty acid guanamine registration number 301-02-0), Mica (accession number 12001-26-2), Atmer 20 (fatty alkyl diethanolamine registration number 107043-84 -5), Pluronic (polyoxypropylene-polyoxyethylene block copolymer registration number 106392-12-5), Tetronic (alkoxylated amine 110617-70-4), Fluura (registration number 7681-49-4) , stearic acid|bow, zinc stearate, Super-Floss anti-caking agent (slip/anti-caking agent registration number 61790-53-2), Zeospheres anti-caking agent 13 200824881 (slip/anti-caking agent) ;Ampacet 40604 (fatty acid decylamine), Kemamide (fatty acid decylamine), Lico_wax fatty acid decylamine, Hypermer B246SF, XNAP, polyethylene glycol monolaurate (antistatic) epoxidized soybean salad oil, talc (hydrated tannic acid) Magnesium), calcium carbonate, behenic acid, pentaerythritol tetrastearic acid, purine acid, epolene E43-Wax, methylcellulose, cocamide (anti-caking agent registration number 61789-19-3), polyvinylpyrrolidone (360,000 MW). Preferred additives are polyvinylpyrrolidone, hard lauric acid and glyceryl monostearate, wherein the weight percent of the additive based on the total weight of the polymer is from about 0.05 to about 1 Torr. The weight percentage is preferably from about 5 to about 3.0 weight percent, most preferably about 2.0 weight percent. In some embodiments, in addition to the additive, the separation of the lens from the lens forming surface can be facilitated by applying a surfactant to the lens forming surface. Examples of suitable surfactants include Tween surfactants, in particular Tween 80 as described in U.S. Patent No. 5,837,314, the disclosure of which is incorporated herein by reference. Furthermore, in some embodiments, the mold of the present invention may contain other polymers such as polypropylene, polyethylene, polystyrene, polymethyl methacrylate, and an alicyclic half (m〇iety) in the main chain. Modified polyolefins and cyclopolymers
稀 fe 類譬如 Atofina Corporation 出品之 Zeonor 和 EOD 〇〇_11。舉例來說，可使用脂環共聚物與聚丙烯之混合物（有 成核作用的二茂金屬催化程序，譬如AT〇FINA EOD 〇〇_11®)’其中脂環共聚物與聚丙烯之重量百分率的比例為 約99 : 1至約2〇 : 80。此混合物可用於模具半體之任一者 或二者，但在一些實施例中最好是將此混合物用在背曲面 14 200824881 上，且丽曲面係由脂環共聚物組成。 101 施例中’第一模具部件102 *第二模具部件 學结構。：或—者亦可包含多層，且每—層可具有不同化 5 10 15 20 和二μ來說，前曲面模具部件102可包含一表面層 ^ ^圖中未示）致使該芯層包含帛一 料且本質上被帛…弟材枓和第二材 表面層中之層覆盍。在任何給定橫截面，存在於該 料的濃度。纽切存在於糾層巾之第一材 一唯持在低π續此貫例，依據本發明，表面層暨芯層被 、准持在低於環境溫度之一溫度的模具結構冷卻。 方法步驟 行的示可在本發明-些實施跑 發明之不同實施其中—些或全部可在本 在步驟200,鉍Ψ 士亦丨Ώ 含-第-靜電電二成 在步驟201，射屮士开，】 含一第一磚…出成型—具備-第二鏡片成型表面且包 3弟一靜電電相第二模具部件。 ^ 且部些;::,j中施行的步驟皿’包含從該第一模 J件和δ亥弟一杈具部件之 杈 在步驟203,可輪送並 牛目電何。 =。更進-步的處理舉更:來-==以 他改性加諸於鏡片模具部件。 4或其 在步驟204,可將—雜蕾+ ^ ^ 静電電何施加於該第一模具部件和 15 200824881 該第二模具部件之一 二模具部件之間夺一，一者以在該第一模具部件與該第 由一腎粼# 靜電電荷差。該電荷舉例來說係經 片成部件定位的靜電棒(譬如距離-背曲面鏡 方成裂表面或w曲面 5 10 15 20 較佳實施例可包含一=成！表面5腿以内）施加。-些 鏡片成型表面2咖二曲面鏡片成型表面或前曲面 诶十甘# 乂内的靜電棒。其他實施例可將一靜電 = 電荷誘發11件定位在對於此ϋ件之設計及欲 ^加之電荷而言為適當的任何距離。 在V驟2G5’利用習知程序將—鏡片構成混合物沈積於 一模穴内。 入在206，使該第一模具部件與一第二模具部件組 合’且在步驟207 ’使該鏡片構成混合物固化形成一眼科鏡 上片：在步驟208，可利用此技藝中已為人知之實務方式分開 该第一模具部件與該第二模具部件並移出鏡片。 在步驟209,可利用自動鏡片檢查（有時亦稱為、、ALI") 设備檢查鏡片並判斷鏡片是否有缺陷。依據本發明，該AU 設備會判斷是否有一鏡片孔洞缺陷發生。鏡片孔洞缺陷發 生率得以藉此判定，且可額外確定是否達成一預定發生率 譬如低於2%或低於5%或低於20%。 ALI舉例來說可包含一攝影機，其將鏡片及模具部件 之影像送到一電腦。該電腦可經由可執行軟體操作分析鏡 片108及模具部件101-102之影像以判斷一鏡片中是否存 在一鏡片孔洞缺陷。該電腦亦可經由可執行軟體操作以判 斷一組多個已成型鏡片之孔洞缺陷發生率水準。在一些實 16 200824881 方β例中’該電腦更可操作以判斷^一組多個已成型鏡片之孔 洞缺陷發生率水準是否逼近或超過一預定閾值量。閾值舉 例來說可包含所處理鏡片之一百分比，譬如5%、10%或 20%。 裝置 10 15 20 今參照圖3, 一方塊圖例示可用於本發明之實施中的處 理站301_304所含裝置。在一些較佳實施例中，處理站 301-309可經由一運輸機構31ι而可存取眼科鏡片100。運 輸機構311舉例來說可包含機械人、輸送器及軌道系統當 中一或多者搭配一運轉構件，此運轉構件可包含由一變速 馬達或其他已知驅動機構（圖中未示）供能的輸送帶、鏈 條、纜索或液力機構。 一些實施例可包含放在集裝架（圖中未示）中的背曲 面模具部件1〇1。此等集裝架可由運輸機構311使其在二或 更多個處理站301-309之間移動。一電腦或其他控制器31〇 可操作地連接於處理站3〇1-3〇9以監測並控制在每一站 301-309進行的程序，而且監測並控制運輸機構311以協調 鏡片在處理站301-309之間的移動。 ° 立處理站3〇1·309舉例來說可包含一用以形成塑膠模且 部件101-102的射出成型站3()1，眼科鏡片可在該塑膠模^ ^件内成型。在-些實施例中，—旦形成模具部件厂用^ 鏡!Γ之模具部件10Μ。2的-或多者得已經 静電电何放電。可利用一靜電充電裝置303譬如靜電棒 17 200824881 將一靜電電荷加諸於用來塑造鏡片之模具部件之一或多者 且在該等模具部件之間產生一靜電電荷差。 在一些實施例中，所施予之電荷可產生一約6〇 kv之 靜電電荷差，此可被實現成在+或一3〇 kv範圍中之任音 5 處。靜電電荷可為在從模具形成到最終組裝當中之任咅處 施加，一較佳場合係在快要到沈積站3〇4之前。沈積站1二 會將一份反應混合物沈積到一模具部件内且一組裝站3〇5 可用來組合已有一靜電電荷差橫跨其間之二或更^個模且 部件。 、八 10 在一些實施例中，反應混合物之聚合作用可為在一具 有文控氧氣暴露程度之環境中進行，在一此實 在無氧環境中進行，因為氧可引發副反應了二== 期望光學品質以及聚合鏡片之透光度。 固化站306可包含用以使反應混合物聚合化的裝置。 15 聚合作用較佳是藉由使反應混合物暴露於一引發源的方式 進行’該引發源舉例來說包含下列—或多者：光化輕射^ 熱。固化站302因而包含為沈積於一模具部件内之反應混 合物提供-引發源的裝置。在一些實施例中，光化輕射可 為源自於燈泡且模具總成在料燈泡下方經過。燈泡可在 20 -平行於燈泡軸線之已知平面中提供_^則丨發聚 之光化輻射強度。 在-些實施例中，-固化站3〇2熱源可有效地使反應 混合物溫度提高到-足以協助聚合作用傳播並抵銷反應混 合物在暴露於光化輕射期間收縮之傾向從而促成更佳聚合 18 200824881 5 10 15 作用的溫度。因此，有些實施例可包含一能夠在反應混合 物聚合期間將反應混合物（在此係指開始聚合化之前及正 在進行聚合的樹脂）之溫度維持在聚合產物之玻璃轉變溫 度以上或其軟化溫度以上的熱源。此溫度可隨反應混合物 中之組份的類型和量而異。整體而言，有些實施例包含能 夠建立並維持約40°C至75°C之溫度的裝置。 在一些實施例中，熱源可包含一管道用以在模具總成 通過光化輻射燈泡底下之時將溫暖氣體譬如妒或空/氣^過 該模具總成暨其周遭。管道末端可配備複數個孔&溫暖氣 體經此通過。依此方式散佈氣體有助於實現殼體下之全區 域的溫度均勻化。模具總成周遭全區域的均^溫度可二二 更為一致的聚合作用。 一拆模站307可包含用以使背曲面模具部件ι〇ι從前 曲面模具部件102分開的裝置。拆模作業舉例來說可利用 機械指狀件及高速機械運動將模具部件撬開而完成。 可利用-自動鏡片檢查站3〇8判斷一幵鏡片1否有一孔 洞缺陷。戎自動鏡片檢查站舉例來說可包含一攝影機，苴 將鏡片及相關模具部件之影像送到一電腦3〇6以2分了 一打包站309可打包一鏡片以供分銷。 八刀 20 鏡片材料 在-些實施例中，本發明之較佳鏡片是由 體類或水娜轉成的軟式_眼鏡，料㈣非偈限|生 包含聚矽氧水减膠類及氟水凝膠類。 19 200824881 本發明之其他較佳實施例可包含etafilcon A、genfilcon A、lenefilcon A、polymacon、acquafilcon A、balafilcon A、 lotrafilcon A、galyfilcon A、senofilcon A、聚石夕氧水凝膠類 的鏡片。其他實施例可包含由預聚物製成的眼科鏡片。本 說明書中提及之以上暨其他專利以引用的方式併入本文 中。 儘管已在以上和圖式中特別說明本發明，熟習此技藝 者會理解到可不脫離本發明之精神及範圍就樣式及細部修 改以上所述内容，本發明之精神及範圍應當僅由隨附申請 專利範圍項之範圍設限。 【圖式簡單說明】 圖1例示一眼科鏡片模具部件和鏡片及緊鄰該等模具 部件之靜電棒的簡圖。 圖2例示可用來施行本發明之方法步驟的方塊圖。 圖3例不一可用來施行本發明之裝置的方塊圖。 【主要元件符號說明】 100 模具總成 101背曲面模具部件 102 前曲面模具部件 103A靜電電荷 103B靜電電荷 104 内凹面 20 200824881 5 10 105 外凸面 108 眼科鏡片 109 靜電充電器件 301 射出成型站 303 靜電充電裝置 304 沈積站 305 組裝站 306 固化站 307 拆模站 308 自動鏡片檢查站 309 打包站 310 電腦 311 運輸機構 21Lean fe types such as Zeonor and EOD 〇〇_11 from Atofina Corporation. For example, a mixture of an alicyclic copolymer and polypropylene (a nucleation catalyst for nucleation, such as AT〇FINA EOD®_11®) can be used, in which the weight percentage of the alicyclic copolymer to the polypropylene The ratio is about 99:1 to about 2:80. This mixture can be used for either or both of the mold halves, but in some embodiments it is preferred to use this mixture on the back surface 14 200824881 and the sinusoidal surface is composed of an alicyclic copolymer. 101 In the embodiment, the first mold member 102 * the second mold member structure. Or or may include multiple layers, and each layer may have a differentization of 5 10 15 20 and two μ, the front curve mold part 102 may include a surface layer (not shown) such that the core layer contains 帛It is essentially and intrinsically smashed... the layers of the material and the surface layer of the second material. The concentration of the material present at any given cross section. Neuch exists in the first material of the refining towel. In this case, the surface layer and the core layer are cooled by a mold structure which is held at a temperature lower than one of the ambient temperatures. The steps of the method steps can be implemented in the present invention - some implementations of the different embodiments of the invention - some or all of which may be in the step 200, the 丨Ώ 丨Ώ 丨Ώ - - - - - - - - - - - - - - - - - - - - - - - - - - - Open,] contains a first brick... out of shape--with a second lens forming surface and a second electro-mechanical second mold part. ^ and some;;:, the step in the j is carried out from the first mold member and the member of the kitchen member. In step 203, the wheel can be rotated. =. The further step-by-step process is to add -== to be modified by the lens mold part. 4 or in step 204, may apply - ray + ^ ^ electrostatic electricity to the first mold part and 15 200824881 one of the second mold parts between the two mold parts, one in the first The mold part is inferior to the electrostatic charge of the first kidney. The charge is applied, for example, to a static bar that is positioned by the component (e.g., a distance-back surface mirrored surface or a w-surface 5 10 15 20 preferred embodiment may include a = surface! 5 legs). - Some lens molding surface 2 coffee two curved lens molding surface or front surface 诶 十甘# 静电 inside the static bar. Other embodiments may position an electrostatic = charge induced 11 piece at any distance appropriate for the design of the element and the charge to be applied. The lens-forming mixture is deposited in a cavity using V-well 2G5' using conventional procedures. At 206, the first mold component is combined with a second mold component and the lens assembly is cured in step 207 to form an ophthalmic mirror: at step 208, the practice known in the art can be utilized. The first mold part and the second mold part are separated and removed from the lens. At step 209, the lens can be inspected using an automated lens inspection (sometimes referred to as an ALI") device to determine if the lens is defective. According to the invention, the AU device determines if a lens hole defect has occurred. The incidence of lens hole defects can be determined by this, and it can be additionally determined whether a predetermined incidence rate is reached, such as less than 2% or less than 5% or less than 20%. ALI, for example, can include a camera that delivers images of the lens and mold components to a computer. The computer can analyze the image of the lens 108 and the mold components 101-102 via executable software to determine if a lens hole defect exists in a lens. The computer can also be operated via executable software to determine the level of hole defect occurrence for a plurality of formed lenses. In some examples, the computer is more operable to determine whether the level of hole defect occurrence of a plurality of formed lenses is approaching or exceeding a predetermined threshold amount. The threshold may, for example, include a percentage of the lens being processed, such as 5%, 10% or 20%. Apparatus 10 15 20 Referring now to Figure 3, a block diagram illustrates the apparatus contained in processing station 301-304 that may be used in the practice of the present invention. In some preferred embodiments, the processing stations 301-309 can access the ophthalmic lens 100 via a transport mechanism 31i. The transport mechanism 311 can include, for example, one or more of a robot, a conveyor, and a track system coupled with a running member that can include power from a variable speed motor or other known drive mechanism (not shown). Conveyor belt, chain, cable or hydraulic mechanism. Some embodiments may include a back curve mold part 1〇1 placed in a pallet (not shown). These pallets can be moved by the transport mechanism 311 between two or more processing stations 301-309. A computer or other controller 31 is operatively coupled to the processing stations 3〇1-3〇9 to monitor and control the procedures performed at each of the stations 301-309, and to monitor and control the transport mechanism 311 to coordinate the lens at the processing station. Movement between 301-309. The vertical processing station 3〇1·309 may, for example, comprise an injection molding station 3()1 for forming a plastic mold and components 101-102 in which an ophthalmic lens can be formed. In some embodiments, the mold part 10 of the mold part factory is formed. 2 - or more have to be electrostatic discharge and discharge. An electrostatic charging device 303, such as an electrostatic bar 17 200824881, can be used to apply an electrostatic charge to one or more of the mold components used to shape the lens and create an electrostatic charge difference between the mold components. In some embodiments, the applied charge can produce an electrostatic charge difference of about 6 〇 kv, which can be achieved at any of the 5 in the range of + or a 3 〇 kv. The electrostatic charge can be applied at any point from mold formation to final assembly, preferably before the deposition station 3〇4. The deposition station 1 will deposit a portion of the reaction mixture into a mold part and an assembly station 3〇5 can be used to combine two or more modules and components that have an electrostatic charge difference across. In some embodiments, the polymerization of the reaction mixture can be carried out in an environment with a controlled degree of oxygen exposure, in an oxygen-free environment, because oxygen can initiate a side reaction. Optical quality and transparency of polymeric lenses. Curing station 306 can include means for polymerizing the reaction mixture. Preferably, the polymerization is carried out by exposing the reaction mixture to an initiation source. The initiation source comprises, by way of example, the following: or more: actinic light radiation. The curing station 302 thus includes means for providing a source of initiation for the reaction mixture deposited in a mold part. In some embodiments, the actinic light shot can be derived from a bulb and the mold assembly passes under the bulb. The bulb can provide an actinic radiation intensity that is entangled in a known plane parallel to the axis of the bulb. In some embodiments, the curing station 3 〇 2 heat source is effective to increase the temperature of the reaction mixture to - sufficient to assist in the propagation of the polymerization and counteract the tendency of the reaction mixture to shrink during exposure to actinic light, thereby facilitating better polymerization. 18 200824881 5 10 15 The temperature of the action. Thus, some embodiments may comprise a temperature capable of maintaining the temperature of the reaction mixture (here, the resin which is polymerized before the polymerization is started) and above the glass transition temperature of the polymerization product or above its softening temperature during the polymerization of the reaction mixture. Heat source. This temperature may vary depending on the type and amount of the components in the reaction mixture. In general, some embodiments include devices capable of establishing and maintaining a temperature of between about 40 ° C and 75 ° C. In some embodiments, the heat source can include a conduit for passing a warm gas such as helium or air/gas through the mold assembly and its surroundings as the mold assembly passes beneath the actinic radiation bulb. The end of the pipe can be equipped with a plurality of holes & warm gas passing through. Dispersing the gas in this manner helps to achieve temperature homogenization throughout the entire housing. The uniformity of the entire area of the mold assembly can be more uniform polymerization. A demolding station 307 can include means for separating the back curved mold member ι ι from the front curved mold member 102. The demolding operation can be accomplished, for example, by mechanical fingers and high-speed mechanical movement to pry the mold parts apart. The automatic lens inspection station 3〇8 can be used to determine whether or not a lens 1 has a hole defect. The automatic lens inspection station may, for example, include a camera, and send images of the lens and associated mold components to a computer 3 to 6 for 2 minutes. A packaging station 309 may package a lens for distribution. Eight-knife 20 lens material In some embodiments, the preferred lens of the present invention is a soft-type spectacles converted from a body or a water smear. The material (4) is not limited to finite water. Gel type. 19 200824881 Other preferred embodiments of the invention may comprise lenses of etafilcon A, genfilcon A, lenefilcon A, polymacon, acquafilcon A, balafilcon A, lotrafilcon A, galyfilcon A, senofilcon A, poly-stone hydrogels. Other embodiments may include ophthalmic lenses made from prepolymers. The above and other patents mentioned in this specification are hereby incorporated by reference. While the invention has been described in detail hereinabove in the foregoing drawings, the embodiments of the invention may be The scope of the patent scope item is limited. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic view showing an ophthalmic lens mold member and a lens and an electrostatic bar adjacent to the mold members. Figure 2 illustrates a block diagram of the steps of the method that can be used to carry out the invention. Figure 3 is a block diagram of a device that can be used to implement the present invention. [Main component symbol description] 100 Mold assembly 101 Back surface mold part 102 Front curve mold part 103A Electrostatic charge 103B Electrostatic charge 104 Concave surface 20 200824881 5 10 105 Outer convex surface 108 Ophthalmic lens 109 Electrostatic charging device 301 Injection molding station 303 Electrostatic charging Apparatus 304 Deposition Station 305 Assembly Station 306 Curing Station 307 Demolition Station 308 Automatic Lens Inspection Station 309 Packing Station 310 Computer 311 Transportation Mechanism 21