WO2015001811A1 - 親水性表面を有するシリコーン含有共重合体成形品を作製する方法及び親水性表面を有するシリコーンハイドロゲルコンタクトレンズ - Google Patents
親水性表面を有するシリコーン含有共重合体成形品を作製する方法及び親水性表面を有するシリコーンハイドロゲルコンタクトレンズ Download PDFInfo
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
- G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
- G02B1/041—Lenses
- G02B1/043—Contact lenses
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
- B29C33/40—Plastics, e.g. foam or rubber
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/003—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor characterised by the choice of material
- B29C39/006—Monomers or prepolymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
- B29D11/00038—Production of contact lenses
- B29D11/00067—Hydrating contact lenses
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
- B29D11/00038—Production of contact lenses
- B29D11/00125—Auxiliary operations, e.g. removing oxygen from the mould, conveying moulds from a storage to the production line in an inert atmosphere
- B29D11/00134—Curing of the contact lens material
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F218/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, of carbonic acid or of a haloformic acid
- C08F218/02—Esters of monocarboxylic acids
- C08F218/04—Vinyl esters
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F226/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a single or double bond to nitrogen or by a heterocyclic ring containing nitrogen
- C08F226/06—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a single or double bond to nitrogen or by a heterocyclic ring containing nitrogen by a heterocyclic ring containing nitrogen
- C08F226/08—N-Vinyl-pyrrolidine
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F230/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and containing phosphorus, selenium, tellurium or a metal
- C08F230/04—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and containing phosphorus, selenium, tellurium or a metal containing a metal
- C08F230/08—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and containing phosphorus, selenium, tellurium or a metal containing a metal containing silicon
- C08F230/085—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and containing phosphorus, selenium, tellurium or a metal containing a metal containing silicon the monomer being a polymerisable silane, e.g. (meth)acryloyloxy trialkoxy silanes or vinyl trialkoxysilanes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F290/00—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups
- C08F290/02—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups on to polymers modified by introduction of unsaturated end groups
- C08F290/06—Polymers provided for in subclass C08G
- C08F290/068—Polysiloxanes
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- G—PHYSICS
- G02—OPTICS
- G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
- G02C7/00—Optical parts
- G02C7/02—Lenses; Lens systems ; Methods of designing lenses
- G02C7/04—Contact lenses for the eyes
- G02C7/049—Contact lenses having special fitting or structural features achieved by special materials or material structures
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2083/00—Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2011/00—Optical elements, e.g. lenses, prisms
- B29L2011/0016—Lenses
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
- C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
- C08F220/10—Esters
- C08F220/20—Esters of polyhydric alcohols or phenols, e.g. 2-hydroxyethyl (meth)acrylate or glycerol mono-(meth)acrylate
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F222/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical and containing at least one other carboxyl radical in the molecule; Salts, anhydrides, esters, amides, imides, or nitriles thereof
- C08F222/10—Esters
- C08F222/1006—Esters of polyhydric alcohols or polyhydric phenols
- C08F222/102—Esters of polyhydric alcohols or polyhydric phenols of dialcohols, e.g. ethylene glycol di(meth)acrylate or 1,4-butanediol dimethacrylate
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F226/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a single or double bond to nitrogen or by a heterocyclic ring containing nitrogen
- C08F226/06—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a single or double bond to nitrogen or by a heterocyclic ring containing nitrogen by a heterocyclic ring containing nitrogen
- C08F226/10—N-Vinyl-pyrrolidone
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F2800/00—Copolymer characterised by the proportions of the comonomers expressed
- C08F2800/20—Copolymer characterised by the proportions of the comonomers expressed as weight or mass percentages
Definitions
- the present invention relates to a method for producing a silicone-containing copolymer molded article having a hydrophilic surface and a silicone hydrogel contact lens having a hydrophilic surface.
- a hydrous soft contact lens generally has a good wearing feeling due to its soft material.
- the oxygen permeability of the conventional lens depends on the water content of the lens. Therefore, attempts were made to increase the water content of the material. However, there is a limit to improving oxygen permeability only by increasing the moisture content of the material. Therefore, recently, as a method for increasing oxygen permeability without depending on the water content, a silicone hydrogel obtained by polymerizing a monomer containing a silicone monomer or a siloxane macromonomer has been developed and commercialized as a lens. Yes.
- a cast mold method is generally used because a uniform product can be produced in large quantities.
- Polypropylene is often used as the material of the mold used in the cast mold manufacturing method because it is inexpensive and easy to mold.
- polypropylene itself is hydrophobic. Therefore, when a silicone-containing copolymer is produced using a polypropylene mold, a hydrophobic monomer is oriented at a portion in contact with the mold surface. For this reason, the surface of the lens made of the obtained polymer exhibits high hydrophobicity.
- a silicone-containing copolymer imparts hydrophilicity by polymerizing a lens and then graft polymerization or plasma treatment.
- such post-treatment involves many steps until hydrophilicity is imparted to the surface, and is not preferable as a mass production method.
- a method of incorporating a high molecular weight hydrophilic polymer as an internal wetting agent into the material there is a method of obtaining a material containing a high molecular weight hydrophilic polymer by polymerizing a polymerization solution in which a high molecular weight hydrophilic polymer such as polyvinylpyrrolidone is dissolved.
- the surface of the material obtained by this method exhibits hydrophilicity without plasma treatment or graft polymerization.
- unpolymerized monomers and oligomers generally remain in the polymer obtained by polymerizing the monomer mixture. If such a monomer or oligomer elutes from the lens during wearing, it may induce eye irritation. Therefore, it is common to extract a monomer or an oligomer from a polymer using an alcohol or an aqueous alcohol solution after polymerization. The higher the concentration of alcohol used for extraction, the better the extraction efficiency, and more unpolymerized monomers and oligomers can be removed in a short time. However, the high molecular weight hydrophilic polymer for imparting the hydrophilicity is only physically entangled in the network structure of the polymer.
- a method of manufacturing a contact lens using a mold die made of a material other than polypropylene for example, a mold for molding formed by using a resin having a water absorption rate in the range of 0.01 to 0.15% by mass, and the water contact angle on the surface thereof is in the range of 65 to 80 degrees. It is known to use a mold for making. This method makes it possible to produce a contact lens with excellent surface water wettability by making it easier for the hydrophilic monomer to orient in the part in contact with the mold. However, this method is not a preferable method. This is because the resin mold has a high water absorption rate of the constituent resin, so that the shape stability after molding is poor, or it is difficult to obtain molding conditions and resin accuracy.
- N-vinyl-2-pyrrolidone which is widely used as a raw material for contact lenses, for the purpose of easily improving the hydrophobicity of the surface of soft contact lenses using silicone-containing copolymers.
- hydrophilic monomers having a vinyl group such as N-methyl-N-vinylacetamide have been proposed.
- Patent Document 1 Japanese Patent Publication No. 7-505169 (Japanese Patent Publication No. 7-505169) (Patent Document 1) combines at least one vinyl-containing monomer, at least one acrylic-containing monomer, and at least one silicone-containing prepolymer. A silicone-containing hydrogel obtained by curing the resulting monomer mixture is disclosed. Examples of at least one vinyl-containing monomer include N-vinyl-2-pyrrolidone and N-methyl-N-vinylacetamide.
- Patent Document 2 JP 2011-219512 A discloses a polymerizable compound having [A] an acryloyloxy group, no silicon atom, and a glass transition temperature of 10 ° C. or less as a homopolymer thereof, A polymerizable composition containing [B] a silicone compound having a polymerizable group and [C] N-vinylpyrrolidinone as monomer components is disclosed.
- Patent Document 3 Japanese Patent Publication No. 2010-510550
- Patent Document 3 includes (A) a silicone-containing monomer represented by general formula I, (B) 3-methacryloyloxypropyltris (trimethylsiloxy) silane, (C A silicone-containing copolymer obtained by polymerizing a polymerization solution containing N) vinylpyrrolidone and (D) at least one other nonionic hydrophilic monomer as a component is disclosed.
- Patent Document 4 includes (a) a silicone monomer having a polyethylene glycol group represented by the general formula (I), (b) at least one hydrophilic monomer having a vinyl group, and (c) A silicone-containing copolymer obtained by polymerizing a solution containing a vinyl group-containing crosslinking agent is disclosed.
- Patent Document 5 discloses a method for producing a silicone-containing copolymer using a mold made of a nonpolar resin.
- the material for lens preparation is a polymerizable silicone monomer and a non-silicone monomer
- the non-silicone monomer is a monomer having a vinyl group such as N-vinylpyrrolidone or N-vinyl-N-methylacetamide.
- N, N-dimethyl is widely used as an amphiphilic monomer having both hydrophilic and lipophilic properties.
- Acrylamide is used.
- This N, N-dimethylacrylamide is widely used as one of the constituent components of a silicone-containing copolymer because it exhibits excellent solubility in silicone monomers and a homogeneous monomer mixture can be prepared.
- N, N-dimethylacrylamide imparts lipophilicity to the copolymer surface after polymerization. For this reason, the wettability of the lens after hydration is poor and surface water repellency is exhibited, which is not preferable. (See the reproduction experiment result shown in Comparative Example 9 of the present application).
- the component [A] is responsible for enhancing the compatibility between the silicone compound [B] and the N-vinylpyrrolidinone [C].
- the [A] component is inferior in hydrophilicity, and TRIS (tris (trimethylsiloxy) silylpropyl methacrylate) used in the examples as the silicone compound of the [B] component is a hydroxyl group or a polyethylene glycol group in the molecular structure. Therefore, the obtained lens surface exhibits high water repellency.
- the obtained polymer is difficult to use as a contact lens without post-treatment such as plasma treatment or graft treatment (see the reproduction experiment result shown in Comparative Example 10 of the present application).
- the monomers (A) and (B) used in the method described in Patent Document 3 are silicone monomers that do not contain a hydroxyl group or polyethylene glycol in the molecular structure. Since these silicone monomers exhibit high hydrophobicity, it is impossible to obtain a monomer mixture homogeneous with N-vinylpyrrolidone. Therefore, a homogeneous monomer mixture is prepared by adding a solvent. However, when a solvent is added to the monomer mixture, it is necessary to remove not only the unpolymerized monomer but also the used solvent after polymerization. As a result, the manufacturing process is not only complicated, but it is not a preferable method even when the influence on the environment is taken into consideration.
- Patent Document 4 discloses a silicone monomer having a polyethylene glycol group as the general formula (I).
- the monomer used in the examples is only a monomer having a siloxane group repeating number m of 4 and an ethylene glycol group repeating number n of 1 (Si-1). Since this monomer has only one ethylene glycol group repeat, the solubility in the monomer having a vinyl group is insufficient due to the small number of hydrophilic sites in the silicone monomer structure. Therefore, a silicone component cannot be used at a high blending ratio, and it is difficult to achieve high oxygen permeability.
- Patent Document 5 discloses, in Examples, a composition containing a silicone monomer having a hydroxyl group in its molecular structure (SIGMA) and N-vinylpyrrolidone (NVP) as lens components (Examples 25, 26, 27, 28). 33, 48, 53, 55, 56).
- solvents such as propanol, decanol, and hexanol are all added to these compositions. For this reason, it is necessary to remove not only the unpolymerized monomer but also the solvent used after the polymerization, which not only complicates the production process, but is not a preferable method in consideration of the influence on the environment.
- the present invention requires a post-treatment for improving the wettability of the surface of the polymer after the polymerization without using a high molecular weight hydrophilic polymer and using a polypropylene mold.
- An object of the present invention is to provide a method capable of producing a silicone-containing copolymer molded product having a hydrophilic surface by a cast mold manufacturing method. Furthermore, without using a high molecular weight hydrophilic polymer and without using a post-treatment for improving the water wettability of the polymer surface of the lens after polymerization, even when using a polypropylene mold.
- An object of the present invention is to provide a silicone hydrogel contact lens having a hydrophilic surface.
- a silicone monomer having at least one (meth) acryloyl group (b) a hydrophilic monomer having at least one vinyl group; (c) at least one crosslinkable monomer; and (d) at least one kind.
- Polymerizing a monomer solution containing a polymerization initiator A method for producing a silicone-containing copolymer molded article having a hydrophilic surface and containing a silicone monomer unit, a hydrophilic monomer unit and a crosslinkable monomer unit,
- the polymerization initiator has a 10-hour half-life temperature (hereinafter abbreviated as T10) of 70 ° C. or higher and 100 ° C.
- T10 of the polymerization initiator contained in the monomer solution Said method, which is carried out in the P2 step which is maintained for 1 hour or more at a higher temperature.
- the polymerization initiator is an azo polymerization initiator or an organic peroxide polymerization initiator.
- the content of the silicone monomer (a) unit is in the range of 20 to 56% by mass, and the content of the hydrophilic monomer (b) unit is in the range of 40 to 60% by mass.
- the silicone monomer (a) is at least one monomer selected from the group consisting of the following (a1) and (a2).
- (A1) one or more silicone monomers containing at least one hydroxyl group and 1 to 4 silicon atoms in one molecule
- (A2) One or more silicone monomers containing at least one polyethylene glycol group and 1 to 4 silicon atoms in one molecule.
- the silicone monomer (a1) is a monomer represented by the following general formula (a1-1) or (a1-2): [Wherein R 1 , R 2 , R 3 and R 4 are methyl groups, R 5 is a hydrogen atom or a methyl group, and a represents an integer of 1 to 3.
- the silicone monomer (a2) is a monomer represented by the following general formula (a2-1).
- R 1 , R 2 , R 3 and R 4 are methyl groups, a represents an integer of 1 to 3, and m is 4 to 8.
- X in the formula is one selected from substituents represented by the following formula (Y1) or (Y2) (wherein R 5 is a hydrogen atom or a methyl group).
- the hydrophilic monomer (b) is one or two selected from N-vinyl-2-pyrrolidone and N-vinyl-N-methylacetamide. The method described.
- crosslinkable monomer (c) is at least one monomer selected from the group consisting of (c1), (c2) and (c3).
- (C1) one or more monomers containing two or more vinyl groups in one molecule;
- (C2) one or more monomers containing two or more allyl groups in one molecule;
- (C3) One or more monomers having two or more (meth) acrylate groups in one molecule.
- the monomer (c1) is one or more selected from 1,4-butanediol divinyl ether, diethylene glycol divinyl ether, and triethylene glycol divinyl ether;
- the monomer (c2) is one or more selected from triallyl isocyanurate, trimethylolpropane diallyl ether, and pentaerythritol triallyl ether,
- the monomer (c3) is ethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, and ethoxylated trimethylolpropane tri ( The method according to [9], which is one or more monomers selected from (meth) acrylate.
- the monomer solution further contains at least one auxiliary monomer selected from the group consisting of a siloxane macromonomer, a silicone monomer that does not contain a hydroxyl group or a polyethylene glycol group in the molecular structure, and a monomer that does not contain a silicon atom in the molecular structure.
- auxiliary monomer selected from the group consisting of a siloxane macromonomer, a silicone monomer that does not contain a hydroxyl group or a polyethylene glycol group in the molecular structure, and a monomer that does not contain a silicon atom in the molecular structure.
- the mold having a hydrophobic cavity surface is a double-sided cast mold for forming a contact lens made of polyalkylene, and the silicone-containing copolymer molded product is a precursor for a silicone hydrogel soft contact lens [1] to [12] The method of any one of these.
- the content of the monomer (b) unit is in the range of 40 to 60% by mass, and the content of the monomer (c1) to (c3) unit is in the range of 0.02 to 4% by mass.
- the silicone-containing copolymer molded article wherein the content of monomer units not containing silicon atoms in the molecular structure is less than 10% by mass.
- (A1) one or more units derived from a silicone monomer containing at least one hydroxyl group and 1 to 4 silicon atoms in one molecule and having a molecular weight of less than 900; (A2) one or more silicone monomer units containing at least one polyethylene glycol group and 1 to 4 silicon atoms in one molecule and having a molecular weight of less than 900, (B) one or more units derived from a hydrophilic monomer having a vinyl group, (C1) one or more monomer units containing two or more vinyl groups in one molecule; (C2) one or more of monomer units containing two or more allyl groups in one molecule, (C3) One or more monomers having two or more (meth) acrylate groups in one molecule.
- (A1) one or more units derived from a silicone monomer containing at least one hydroxyl group and 1 to 4 silicon atoms in one molecule and having a molecular weight of less than 900; (A2) one or more silicone monomer units containing at least one polyethylene glycol group and 1 to 4 silicon atoms in one molecule and having a molecular weight of less than 900, (B) one or more units derived from a hydrophilic monomer having a vinyl group, (C1) one or more monomer units containing two or more vinyl groups in one molecule; (C2) one or more of monomer units containing two or more allyl groups in one molecule, (C3) One or more monomers having two or more (meth) acrylate groups in one molecule (e) One or more macromonomers of the general formulas (C1) and (C2) Wherein (C1), R 7 is a hydrogen atom or a methyl group, r is 0 ⁇ 10, p is 8-60.
- R 8 is a hydrogen atom or a methyl group, q is 9 to 15, and t is 0 to 3.
- the silicone monomer (a1) is a monomer represented by the following general formula (a1-1) or (a1-2): [Wherein R 1 , R 2 , R 3 and R 4 are methyl groups, R 5 is a hydrogen atom or a methyl group, and a represents an integer of 1 to 3. ],
- X in the formula is one selected from substituents represented by the following formula (Y1) or (Y2) (wherein R 5 is a hydrogen atom or a methyl group).
- the hydrophilic monomer (b) is one or two selected from N-vinyl-2-pyrrolidone and N-vinyl-N-methylacetamide.
- the monomer (c1) is one or more selected from 1,4-butanediol divinyl ether, diethylene glycol divinyl ether, and triethylene glycol divinyl ether;
- the monomer (c2) is one or more selected from triallyl isocyanurate, trimethylolpropane diallyl ether, and pentaerythritol triallyl ether, and the monomer (c3) is ethylene glycol di (meta) ) Acrylate, triethylene glycol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, and ethoxylated trimethylolpropane tri (meth) acrylate, one or more
- the silicone-containing copolymer molded article according to any one of [15] to [20], which is a monomer of [22]
- the silicone monomer (a1) and (a2) unit content is in the range of 20 to 56%
- the silicone-containing copolymer molded article according to any one of [16] to [22], wherein the content of the siloxane macromonomer unit (e) is 25% by mass or less.
- the silicone-containing copolymer molded article includes at least one additional monomer selected from the group consisting of a silicone monomer unit that does not contain a hydroxyl group or a polyethylene glycol group in the molecular structure, and a monomer unit that does not contain a silicon atom in the molecular structure.
- the hydrophilic surface having a contact angle with respect to pure water of 60 ° or less is obtained without subjecting the lens-shaped material after polymerization to post-treatment for improving the water wettability of the surface.
- [26] [14] A silicone hydrogel soft contact lens precursor which is a silicone-containing copolymer molded article according to any one of [14] to [25] and has a contact lens shape.
- a silicone hydrogel soft contact lens wherein the silicone hydrogel soft contact lens precursor according to [26] is hydrated with physiological saline or a storage solution for soft contact lenses.
- the soft contact lens according to [29] wherein the water-containing silicone hydrogel soft contact lens has a replacement frequency of one day or two weeks.
- A1 one or more units derived from a silicone monomer containing at least one hydroxyl group and 1 to 4 silicon atoms in one molecule;
- A2) one or more silicone monomer units containing at least one polyethylene glycol group and 1 to 4 silicon atoms in one molecule;
- B) one or more units derived from a hydrophilic monomer having a vinyl group,
- C1 one or more monomer units containing two or more vinyl groups in one molecule;
- C2 one or more of monomer units containing two or more allyl groups in one molecule,
- C3 One or more monomers having two or more (meth) acrylate groups in one molecule.
- the silicone monomer (a1) is a monomer represented by the following general formula (a1-1) or (a1-2): [Wherein R 1 , R 2 , R 3 and R 4 are methyl groups, R 5 is a hydrogen atom or a methyl group, and a represents an integer of 1 to 3. ],
- X in the formula is one selected from substituents represented by the following formula (Y1) or (Y2) (wherein R 5 is a hydrogen atom or a methyl group).
- Y1 or (Y2) wherein R 5 is a hydrogen atom or a methyl group.
- R 5 is a hydrogen atom or a methyl group.
- the monomer (c1) is one or more selected from 1,4-butanediol divinyl ether, diethylene glycol divinyl ether, and triethylene glycol divinyl ether;
- the monomer (c2) is one or more selected from triallyl isocyanurate, trimethylolpropane diallyl ether, and pentaerythritol triallyl ether, and the monomer (c3) is ethylene glycol di (meta) ) Acrylate, triethylene glycol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, and ethoxylated trimethylolpropane tri (meth) acrylate, one or more
- the silicone-containing copolymer molded article according to any one of [015] to [017], which is a monomer of [019]
- the content of the silicone monomer (a1) and (a2) units is in the range
- the silicone-containing copolymer molded article is at least selected from the group consisting of a siloxane macromonomer unit, a silicone monomer unit that does not contain a hydroxyl group or a polyethylene glycol group in the molecular structure, and a monomer unit that does not contain a silicon atom in the molecular structure.
- the silicone-containing copolymer molded article according to any one of [015] to [019], further containing one kind of additional monomer unit.
- the hydrophilic surface having a contact angle with respect to pure water of 60 ° or less is obtained without subjecting the lens-shaped material after polymerization to post-treatment for improving the water wettability of the surface.
- a silicone hydrogel soft contact lens precursor which is a silicone-containing copolymer molded article according to any one of [015] to [021] and has a contact lens shape.
- the silicone hydrogel soft contact lens in the water-containing state is a soft contact lens according to [023] or [024], which is a soft contact lens whose replacement frequency is up to one month.
- [026] [025] The soft contact lens according to [025], wherein the water-containing silicone hydrogel soft contact lens has a replacement frequency of one day or two weeks.
- the present invention even if it is a silicone-containing copolymer obtained by curing using a double-sided cast mold of a hydrophobic material such as polypropylene, the wettability of the surface to the lens-shaped material after polymerization It is possible to provide a method for producing a silicone-containing copolymer molded article having a hydrophilic surface without including a post-treatment for improving the water resistance and a high molecular weight hydrophilic polymer for enhancing the water wettability of the surface. it can. Furthermore, according to the present invention, a silicone hydrogel contact lens having a hydrophilic surface can be provided.
- FIG. 1 is a 1 H-NMR spectrum of the compound obtained in Synthesis Example 1.
- FIG. 2 is a MALDI-TOF MS spectrum of the compound obtained in Synthesis Example 1.
- FIG. 3 is a 1 H-NMR spectrum of the compound obtained in Synthesis Example 2.
- FIG. 4 is a MALDI-TOF MS spectrum of the compound obtained in Synthesis Example 2.
- FIG. 5 shows the measurement results (images) of contact angles with respect to pure water of the silicone-containing copolymer molded articles obtained in Examples 1 to 4 and Comparative Examples 1 and 2.
- the method for producing a silicone-containing copolymer molded article having a hydrophilic surface includes the following steps: (A) at least one silicone monomer, (b) a hydrophilic monomer having at least one vinyl group, (c) at least one crosslinkable monomer, and (d) a monomer containing at least one polymerization initiator Polymerize the solution, This is a method for producing a silicone-containing copolymer molded article having a hydrophilic surface and containing a silicone monomer unit, a hydrophilic monomer unit, and a crosslinkable monomer unit.
- the polymerization initiator has a 10-hour half-life temperature (T10) of 70 ° C. or higher and 100 ° C. or lower. Further, the polymerization is carried out for a period of at least 1 hour within a temperature range from T10 of the polymerization initiator contained in the monomer solution to 35 ° C. lower than T10, and T10 of the polymerization initiator contained in the monomer solution. Including a P2 step of maintaining at a higher temperature for 1 hour or more.
- T10 10-hour half-life temperature
- the mold used in the method of the present invention is a mold having a hydrophobic cavity surface.
- the hydrophobicity of the hydrophobic cavity surface means, for example, that the contact angle with pure water is 90 ° or more.
- the hydrophobicity of the cavity surface means the hydrophobicity caused by the cavity surface or the mold material, and does not require any special hydrophobicity treatment. However, it is not intended to exclude those subjected to special hydrophobicity treatment on the cavity surface in consideration of the peelability after polymerization.
- limiting in the upper limit of the contact angle with respect to the pure water of the hydrophobic cavity surface Generally it is 120 degrees. However, it is not intended to be limited to this angle.
- the mold can be a combined mold having convex and concave curvatures, and can be made of a material such as metal or resin. However, it is preferable that the material has good peelability after polymerization and is excellent in solvent resistance and heat resistance.
- the mold having the hydrophobic cavity surface is preferably made of resin, for example.
- a resin mold is preferable because a mold having a shape necessary for a desired lens design can be easily manufactured. These resin materials are preferably selected from those having low molding shrinkage, good surface transferability from metal, and excellent dimensional accuracy and solvent resistance, and polypropylene is preferable from the viewpoint of price and availability.
- polypropylene it is not limited to polypropylene, and for example, polyethylene, polyethylene terephthalate, polymethylpentene, polysulfone, polyphenylene sulfide, cyclic olefin copolymer, ethylene vinyl alcohol copolymer, and the like may be used.
- the monomer solution comprises (a) a silicone monomer having at least one (meth) acryloyl group, (b) a hydrophilic monomer having at least one vinyl group, (c) at least one crosslinkable monomer, and (d) Contains at least one polymerization initiator.
- the silicone monomer (a) is a silicone monomer having a (meth) acryloyl group.
- the silicone monomer (a) has one (meth) acryloyl group per molecule.
- a (meth) acryloyl group means either a methacryloyl group or an acryloyl group.
- the silicone monomer suitably has a molecular weight of less than 900. The reason will be described later.
- the silicone monomer (a) is preferably a silicone monomer containing 1 to 4 silicon atoms in one molecule and having at least one hydroxyl group or polyethylene glycol group in the molecule.
- a silicone-containing copolymer molded article having excellent hydrophilicity By using a silicone monomer having at least one hydroxyl group or polyethylene glycol group in the molecule, a silicone-containing copolymer molded article having excellent hydrophilicity can be obtained.
- a silicone monomer can be, for example, the following (a1) or (a2) silicone monomer.
- (A1) one or more silicone monomers containing at least one hydroxyl group and 1 to 4 silicon atoms in one molecule
- A2 One or more silicone monomers containing at least one polyethylene glycol group and 1 to 4 silicon atoms in one molecule
- the silicone monomer (a1) can be, for example, a monomer represented by the following general formula (a1-1) or (a1-2). [Wherein R 1 , R 2 , R 3 and R 4 are methyl groups, R 5 is a hydrogen atom or a methyl group, and a represents an integer of 1 to 3. ],
- the silicone monomer (a2) can be, for example, a monomer represented by the following general formula (a2-1). [Wherein R 1 , R 2 , R 3 and R 4 are methyl groups, a represents an integer of 1 to 3, and m is 4 to 8. X in the formula is one selected from substituents represented by the following formula (Y1) or (Y2) (wherein R 5 is a hydrogen atom or a methyl group). ]
- the silicone monomer (a1) or (a2) can also be represented by, for example, the following general formula (I).
- R 1 , R 2 , R 3 and R 4 are methyl groups, a represents an integer of 1 to 3, n represents 0 or 1, and m represents 0 or 4 to 8. However, when n is 1, m is 0, and when n is 0, m is 4 to 8 (value as a repeated average value).
- X in the formula is one selected from substituents represented by the formulas (Y1) to (Y2). ]
- the silicone monomer having a molecular weight of less than 900 prevents a decrease in the strength of the resulting polymer, prevents a decrease in the silicon content in one monomer molecule, and provides sufficient oxygen permeability. It is appropriate from the viewpoint of being able to do it.
- the number average molecular weight is less than 900 when the number average molecular weight is calculated in terms of polystyrene as measured by gel permeation chromatography.
- the silicone monomer preferably has a molecular weight in the range of 400 to 850.
- the silicone monomer is used.
- the compatibility with a hydrophilic monomer for example, a hydrophilic monomer having a vinyl group
- a mixed solution polymerization solution
- the silicone monomer having such a structure is a known compound.
- the silicone monomer (a1) Japanese Patent Laid-Open No. 55-15110 (US Pat. No. 4,139,692), Japanese Patent Laid-Open No. 63-163811, Japanese Patent Laid-Open No. 2001-323024, Japanese Patent Laid-Open No. 2002-113089 (US 2004). No. 014921), Japanese Patent Application Laid-Open No. 2002-182167 and US Pat. No. 4,395,496, and the silicone monomer (a2) is one of the contact lens materials disclosed in Japanese Patent Application Laid-Open No. 4-332760. It is disclosed as one. The entire description of these publications is specifically incorporated herein by reference.
- the silicone monomer used in the present invention is particularly preferably a monomer represented by the following structural formulas A1 to A7.
- R 6 is a hydrogen atom or a methyl group
- m is 4 to 8.
- structural isomers such as the following formulas (B1) and (B2) exist in the monomer synthesis process.
- a mixture of structural isomers may be used, or a mixture consisting of only one of the structures may be used.
- formula (A3) no structural formula is shown, but structural isomers exist as in formulas (A1) and (A2).
- R 6 is a hydrogen atom or a methyl group
- Examples of a method for producing a silicone monomer having a polyethylene glycol group in the molecular structure include the following.
- polyethylene glycol group means an ethylene glycol repeating number (average value) in the range of 4 to 8. That is, one end of ethylene glycol such as tetraethylene glycol, pentaethylene glycol, hexaethylene glycol, heptaethylene glycol, octaethylene glycol, etc. is allylated, and then hydrosilylation reaction causes tris (trimethylsiloxy) silyl group or methylbis (trimethyl) React with siloxy) silyl group.
- a desired silicone monomer by reacting a compound having a methacryloyl group at one terminal hydroxyl group (for example, methacryl chloride, 2-isocyanatoethyl methacrylate).
- a compound having a methacryloyl group at one terminal hydroxyl group for example, methacryl chloride, 2-isocyanatoethyl methacrylate.
- the monomers A4 to A7 used in the present invention the value of m may have a distribution, and the average value thereof may be 4 to 8.
- the number of glycol repeats can be reduced by using the number of glycols to be a single repeat number (for example, when m is 4 and other numbers (for example, 3 and 5 are not included)) after synthesis. You may make it have no distribution. In order to reduce variations in various physical property values such as mechanical strength and water wettability of the obtained lens, it is preferable that the number of polyethylene glycol repeats has no distribution and is a single repeat number.
- m is 4 or more, a homogeneous monomer mixture can be obtained by being excellent in compatibility with other copolymerization components.
- m is 8 or less, the molecular structure is not too long and the lens machine It is preferable because a decrease in the mechanical strength can be prevented.
- average value is applied when the number of repeating polyethylene glycol groups in the silicone monomer structure has a distribution, and the precursor or final structure as a starting material is analyzed by 1 H-NMR analysis. And the number of repetitions calculated using the peak integrated intensity ratio of the ethylene oxide unit.
- the content of the silicone monomer in the monomer solution is based on the total amount of all monomers. For example, it is preferably 20 to 56% by mass.
- the content of the silicone monomer is more preferably 20 to 55% by mass, and further preferably 25 to 52% by mass.
- the hydrophilic monomer is a hydrophilic monomer having a vinyl group.
- the hydrophilic monomer having a vinyl group can be, for example, one or two selected from N-vinyl-2-pyrrolidone and N-vinyl-N-methylacetamide.
- a hydrophilic monomer having a vinyl group is used.
- after polymerization without using a special post-treatment or a high molecular weight hydrophilic polymer, and even when polypropylene is used as a mold material, it is easy to form a silicone-containing copolymer having a hydrophilic surface. You can get goods.
- the content of the hydrophilic monomer having a vinyl group in the monomer solution in the method for producing a silicone-containing copolymer molded article of the present invention and a contact lens produced from the silicone-containing copolymer molded article described later is the sum of all monomers.
- the amount is preferably 40 to 60% by mass based on the amount.
- the crosslinkable monomer can crosslink a hydrophilic monomer having a vinyl group or a monomer having a (meth) acrylate group to impart heat resistance and solvent resistance to the copolymer.
- the content of the crosslinkable monomer in the monomer solution is suitably in the range of 0.02 to 4% by mass with respect to the total amount of all monomers.
- the crosslinkable monomer can be, for example, at least one monomer selected from the group consisting of (c1), (c2) and (c3).
- (C1) one or more monomers containing two or more vinyl groups in one molecule
- (C2) one or more monomers containing two or more allyl groups in one molecule
- (C3) One or more monomers having two or more (meth) acrylate groups in one molecule.
- “(meth) acrylate group” means an acrylate group or a methacrylate group.
- crosslinkable monomer (c1) contains two or more vinyl groups in one molecule, it is effective for crosslinking the hydrophilic monomer (b).
- the crosslinkable monomer (c1) can be, for example, one or more selected from 1,4-butanediol divinyl ether, diethylene glycol divinyl ether, and triethylene glycol divinyl ether.
- crosslinkable monomer (c2) contains two or more allyl groups in one molecule, it is effective for crosslinking the hydrophilic monomer (b).
- the crosslinkable monomer (c2) can be, for example, one or more selected from triallyl isocyanurate, trimethylolpropane diallyl ether, and pentaerythritol triallyl ether.
- the crosslinkable monomer (c3) Since the crosslinkable monomer (c3) has a “(meth) acrylate” group, it tends to selectively crosslink with a silicone monomer having a “(meth) acrylate” group belonging to the monomer (a). Furthermore, the monomer (c3) tends to selectively crosslink with a siloxane macromonomer described later, a silicone monomer that does not contain a hydroxyl group or a polyethylene glycol group in the molecular structure, and a monomer that does not contain a silicon atom in the molecular structure.
- Examples of the monomer (c3) include ethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, and ethoxylated trimethylolpropane. It can be one or more selected from tri (meth) acrylates.
- the content of the crosslinkable monomers (c1) and (c2) is preferably in the range of 0.02 to 1% by mass with respect to the total amount of all monomers.
- the amount of the crosslinkable monomers (c1) and (c2) used is 0.02% by mass or more, heat resistance and solvent resistance are imparted. It is possible to prevent the polymer from becoming brittle.
- the crosslinkable monomers (c1) and (c2) are more preferably 0.1 to 0.8% by mass, respectively.
- the content of the crosslinkable monomer (c3) is preferably 0.1 to 3% by mass with respect to the total amount of all monomers.
- the amount of the crosslinkable monomer (c3) used is 0.1% by mass or more, mechanical strength and durability can be imparted, and by making it 3% by mass or less, the resulting soft contact lens is prevented from becoming brittle. I can do it.
- the content of the crosslinkable monomer (c3) is more preferably 0.2 to 2% by mass.
- the crosslinkable monomers (c1), (c2) and (c3) may be used alone or in combination. When used in combination, the total content is 0.02 to 4 mass. % Range.
- the polymerization initiator has a 10-hour half-life temperature (T10) of 70 ° C. or higher and 100 ° C. or lower.
- T10 10-hour half-life temperature
- the P1 step 35 ° C. lower than the polymerization initiator T10 to T10, which will be described in detail later
- the hydrophilicity which is the object of the present invention is obtained through a two-stage polymerization process of maintaining the temperature within a range of 1 hour or longer) and P2 process (maintaining at a temperature higher than T10 of the polymerization initiator for 1 hour or longer).
- a silicone-containing copolymer molded product having a conductive surface can be obtained.
- polymerization initiator examples include an azo polymerization initiator or an organic peroxide polymerization initiator having a T10 of 70 ° C. or higher and 100 ° C. or lower.
- polymerization initiator having T10 of 70 ° C. or higher and 100 ° C. or lower include the following compounds.
- T10 of the polymerization initiator can be calculated by measurement, the published value of the manufacturer may be referred to.
- the content of the polymerization initiator can be determined in consideration of the composition of the monomer mixed solution, the conditions of the polymerization process, and the like. Can be. The range is preferably 0.2 to 0.9% by mass.
- the above polymerization initiator and polymerization conditions are used in combination. It is known that the reactivity of the monomer varies greatly depending on the functional group, and in particular, the reactivity of the monomer having a methacryloyl group or acryloyl group is significantly different from the monomer having a vinyl group.
- the half-life of the polymerization initiator is a convenient index representing the decomposition rate at a constant temperature. Optimization of the polymerization reaction is also performed in consideration of T10. However, when a copolymer is produced using a plurality of monomer mixtures, it cannot be easily optimized from T10 alone.
- the direction of optimization differs depending on the selection of physical properties that serve as an optimization index.
- T10 is 70 ° C. or higher and 100 ° C. or lower. It was found that a silicone-containing copolymer molded article having a hydrophilic surface can be obtained by using a polymerization initiator in the range, and further through a polymerization process including P1 and P2 steps described later.
- the polymerization reaction proceeds relatively slowly due to the slow decomposition rate of the initiator, and a block in which the same type of monomers are preferentially polymerized is formed.
- the curing proceeds while maintaining the block to some extent.
- a portion where a monomer having a methacryloyl group or an acryloyl group is richly cured and a portion where a hydrophilic monomer having a vinyl group is richly cured are separately formed.
- 1,1′-azobis (cyanocyclohexane) is described as a polymerization initiator (third line on page 14).
- 1,1'-azobis (cyanocyclohexane) has a T10 of 88 ° C.
- the polymerization initiator used in the examples is V-64, 2,2′-azobis-2-methylpropanenitrile, [CAS: 78-67-1, T10: 65 ° C.] (T10 is less than 70 ° C. Only).
- a silicone-containing copolymer having a hydrophilic surface is obtained by using a polymerization initiator having a T10 of 70 ° C. or higher and 100 ° C. or lower and undergoing a polymerization process including P1 and P2 steps described later. There is no suggestion that a coalesced molded product can be obtained.
- Patent Document 5 2,2′-azobis (2,4-dimethylpentanenitrile) [CAS: 4419-11-8, T10: 51 ° C.] and azobisisobutyronitrile [CAS] are used in Examples. : 78-67-1, T10: 65 ° C] is used as the polymerization initiator.
- a silicone-containing copolymer having a hydrophilic surface is formed by using a polymerization initiator having a T10 of 70 ° C. or more and 100 ° C. or less and undergoing a polymerization process including P1 and P2 steps described later. There is no suggestion that you can get a product.
- the monomer solution includes at least one monomer selected from the group consisting of the following (a1) and (a2), at least one monomer selected from the group consisting of (b), and (c1), (c2) and (c3) And at least one monomer selected from the group consisting of: (A1) one or more silicone monomers containing at least one hydroxyl group and 1 to 4 silicon atoms in one molecule; (A2) one or more silicone monomers containing at least one polyethylene glycol group and 1 to 4 silicon atoms in one molecule; (B) one or more hydrophilic monomers having a vinyl group, (C1) one or more monomers containing two or more vinyl groups in one molecule; (C2) One or more monomers having two or more allyl groups in one molecule (c3) One or more monomers having two or more (meth) acrylate groups in one molecule .
- the silicone monomer (a1) to (a2) unit content of the silicone-containing copolymer molded product is in the range of 20 to 56% by mass, and the hydrophilic monomer (b) unit content is 40 to 60% by mass. %, And the content of the crosslinkable monomers (c1) to (c3) units is in the range of 0.02 to 4% by mass.
- the monomer solution further contains at least one auxiliary monomer selected from the group consisting of a siloxane macromonomer, a silicone monomer that does not contain a hydroxyl group or a polyethylene glycol group in the molecular structure, and a monomer that does not contain a silicon atom in the molecular structure. can do.
- the siloxane macromonomer means a monomer having a molecular weight of 900 or more.
- the silicone-containing copolymer of the present invention does not contain a siloxane macromonomer or a hydroxyl group or a polyethylene glycol group in the molecular structure in order to improve oxygen permeability. Silicone monomers and monomers that do not contain silicon atoms in the molecular structure can be included as components.
- siloxane macromonomer examples include macromonomers described in JP-A-2001-311917, JP-A-2001-183502, and JP-T-11-502949. The entire description of these publications is specifically incorporated herein by reference.
- macromonomers represented by the following general formulas (C1) and (C2) are preferable.
- R 7 is a hydrogen atom or a methyl group
- r is 0 to 10
- p is 8 to 60.
- r is more preferably 0 to 8, and further preferably 0 to 5.
- p is more preferably 8 to 50, and further preferably 8 to 40.
- R 8 is a hydrogen atom or a methyl group
- q is 9 to 15, and t is 0 to 3.
- q is more preferably 9 to 13, and further preferably 9 to 12.
- t is preferably 0-2.
- silicone monomers having no hydroxyl group or polyethylene glycol group in the molecular structure include tris (trimethylsiloxy) - ⁇ -methacryloxypropylsilane, tris (trimethylsiloxy) - ⁇ -acryloxypropylsilane, and methacryloyloxyethyl succinic acid.
- R 8 is a hydrogen atom or a methyl group, q is 4 to 8, and t is 0 to 3. q is preferably 4-6. t is preferably 0-2.
- siloxane macromonomers and silicone monomers that do not contain a hydroxyl group or polyethylene glycol group in the molecular structure can be used in the range of 0 to 25% by mass with respect to the monomer solution.
- a homogeneous monomer mixed solution can be prepared without causing the monomer mixed solution to become cloudy, and the water wettability of the lens surface is poor. Can be prevented.
- Examples of monomers that do not contain a silicon atom in the molecular structure include 2-hydroxyethyl (meth) acrylate, methacrylic acid, methyl (meth) acrylate, ethyl (meth) acrylate, n-butyl (meth) acrylate, 2-methoxy
- One or more monomers selected from ethyl (meth) acrylate, 2-methacryloyloxyethyl phosphorylcholine and the like can be mentioned, and they can be used in a range of less than 10% by mass.
- N, N-dimethylacrylamide which is often used as a constituent component of the silicone-containing copolymer, because it deteriorates the water wettability of the lens surface after polymerization.
- the content of the monomer not containing a silicon atom in the molecular structure is more preferably 2 to 8% by mass, and further preferably 3 to 7% by mass.
- (meth) acrylate means both acrylate and methacrylate.
- the silicone-containing copolymer molded article of the present invention is used as a copolymer component in order to impart ultraviolet absorption ability to the obtained soft contact lens or to color for the purpose of improving visibility, for example, polymerizable ultraviolet absorption.
- An agent, a polymerizable dye, and the like can be contained.
- the polymerizable ultraviolet absorber examples include 5-chloro-2- [2-hydroxy-5- ( ⁇ -methacryloyloxyethylcarbamoyloxyethyl)] phenyl-2H-benzotriazole, 2- [2-hydroxy -5- ( ⁇ -Methacryloyloxyethylcarbamoyloxyethyl)] phenyl-2H-benzotriazole, 5-chloro-2- [2-hydroxy-4- (p-vinylbenzyloxy-2-hydroxypropyloxy)] phenyl -2H-benzotriazole, 4-methacryloxy-2-hydroxybenzophenone, 2- (2'-hydroxy-5'-methacryloxyethylphenyl) -2H-benzotriazole, and the like.
- the polymerizable dye examples include 1,4-bis (4-vinylbenzylamino) anthraquinone, 1-p-hydroxybenzylamino-4-p-vinylbenzylaminoanthraquinone, 1-anilino-4-methacryloylaminoanthraquinone. 1,4-bis [4- (2-methacryloxyethyl) phenylamino] -9,10-anthraquinone, 4- (5-hydroxy-3-methyl-1-phenyl-4-pyrazolylmethylene) -3-methacryl And amino-1-phenyl-2-pyrazolin-5-one.
- phthalocyanine dyes such as AlcianBlue8GX and AlcianGreen2GX can be incorporated into the contact lens material of the present invention as a colorant.
- the contents of the polymerizable ultraviolet absorber and the polymerizable dye are influenced by the thickness of a lens produced from this material, the content is 5% by mass or less, particularly preferably 0.8%, based on the total amount of the copolymer components. It is suitable that the content is 02 to 3% by mass.
- the amount used is 5% by mass or less, it is possible to prevent the mechanical strength of the obtained contact lens from being lowered, and it is also preferable from the viewpoint of the safety of the contact lens that is in direct contact with the living body.
- the monomer solution is polymerized in a mold cavity having a hydrophobic cavity surface.
- the polymerization is performed at a temperature higher than T10 of the polymerization initiator contained in the monomer solution, and the P1 step of maintaining the polymerization initiator contained in the monomer solution for at least 1 hour within a temperature range from T10 to 35 ° C lower than T10.
- the polymerization in the P1 step may be referred to as “gelation”, and the polymerization in the P2 step may be referred to as “cure”.
- the polymerization initiator contained in the monomer solution is maintained for at least 1 hour within a temperature range from T10 to 35 ° C. lower than T10.
- the maintenance temperature in the P1 step is preferably in the range of 10 ° C. lower than T10 to 35 ° C. lower than T10, more preferably in the range of 15 ° C. lower than T10 to 35 ° C. lower than T10, and more preferably Is in the range of 20 ° C. below T10 to 35 ° C. below T10.
- the P2 step is performed for 1 hour or more at a temperature higher than the T10 of the polymerization initiator contained in the monomer solution.
- the maintenance temperature in the P2 step is preferably in the range of 5 ° C. higher than T10 to 50 ° C. higher than T10, more preferably in the range of 10 ° C. higher than T10 to 50 ° C. higher than T10, and more preferably Is in the range of 15 ° C. higher than T10 to 50 ° C. higher than T10.
- the monomer solution composed of the above components is polymerized after being injected into, for example, a contact lens manufacturing mold having a contact lens shape.
- a mold immediately after molding may be used, or a mold stocked for about 10 to 40 hours may be used in order to stabilize the curvature of the mold.
- the pressure on the mold is sufficiently reduced to remove substances that affect the reaction such as moisture and oxygen on the mold surface, and after purging with an inert gas such as nitrogen or argon, the monomer solution is put into the mold. It may be injected.
- it may be used after the oxygen dissolved in the monomer solution is removed by bubbling the monomer solution with an inert gas such as nitrogen or argon in advance. You may use without removing.
- polymerization method it is preferable to employ polymerization by heat by blending the polymerization initiator.
- the heating conditions are as described above.
- the atmosphere during polymerization may be in the air, but it is preferable to perform polymerization in an inert gas atmosphere such as nitrogen or argon for the purpose of improving the polymerization rate of the monomer and reducing the amount of unreacted monomer. .
- the pressure in the polymerization furnace is preferably 1 kgf / cm 2 or less.
- Suitable diluents may be any that dissolves homogeneously with the monomer components used, such as alcohols (eg, ethanol, tert-butanol, n-hexanol, octanol), esters (eg, ethyl acetate, Propyl acetate, methyl propionate, ethyl propionate, butyl propionate) and the like.
- alcohols eg, ethanol, tert-butanol, n-hexanol, octanol
- esters eg, ethyl acetate, Propyl acetate, methyl propionate, ethyl propionate, butyl propionate
- the usage-amount of a diluent is 20 mass% or less with respect to the total amount of a monomer component.
- the polymerization schedule is maintained for at least 1 hour within a temperature range from T10 of the polymerization initiator contained in the monomer solution to 35 ° C. lower than T10.
- the holding time in the P1 step is preferably 5 hours or more and 14 hours or less. This is because, when the holding time is 5 hours or longer, a good hydrophilic surface is easily obtained when the film is subsequently cured, and when the lens is polymerized, a circular lens is easily obtained after swelling. . However, if it exceeds 14 hours, the total polymerization time (the time in which “gelation” and “cure” are combined) becomes too long, resulting in poor production efficiency.
- the holding time for this “gelation” is more preferably 6 to 12 hours.
- the maintenance time means a time not including the temperature raising time to the maintenance (holding) temperature in the P1 step, and the temperature raising time within the maintenance (holding) temperature range is the maintenance time ( Holding time is also synonymous). Similarly, it means a time not including the temperature rise time from the maintenance (holding) temperature in the P1 process to the maintenance (holding) temperature in the P2 process, and the temperature rising time within the maintenance (holding) temperature range is the maintenance time. (Retention time is also synonymous).
- the maintenance time of the polymerization initiator at a temperature higher than T10 is 1 hour or longer, and is preferably in the range of 4 hours to 10 hours, for example, from the viewpoint of completion of the polymerization.
- the temperature can be maintained without being changed during each process, but can be varied within a predetermined range during each process.
- the temperature can be increased stepwise within a temperature range from T10 of the polymerization initiator to 35 ° C. lower than T10. More specifically, for example, (i) it can be maintained for a certain time t1 at a temperature 30 ° C. lower than T10, and then (ii) can be maintained at a temperature 20 ° C.
- the maintenance time of 1 hour or more in the P1 process means the time from the start of heating in (i) to the end of heating in (ii) including the temperature rising time from (i) to (ii). .
- the temperature can be raised stepwise at a temperature higher than T10 of the polymerization initiator. More specifically, for example, (iii) it can be maintained at a temperature 10 ° C. higher than T10 for a certain time t1, and then (iv) can be maintained at a temperature 20 ° C. higher than T10 for a certain time t2.
- the maintenance time of 1 hour or more in the P2 process means the time from the start of heating in (iii) to the end of heating in (iv) including the temperature rising time from (iii) to (iv). .
- the temperature can be raised stepwise to a maximum temperature of 130 ° C. or lower, and further heated, for example, for 4 to 10 hours to complete the polymerization.
- the polymerization schedule (set temperature and time) in the P1 step and the P2 step is not intended to be limited to the above example, and can be appropriately selected.
- the copolymer molded product (eg, lens shape) removed from the mold after polymerization is extracted with unsolved monomers and oligomers with a solvent (eg, methanol, ethanol, isopropyl alcohol, methanol aqueous solution, ethanol aqueous solution, isopropyl alcohol aqueous solution, etc.). And can be removed. Thereafter, the desired hydrous silicone hydrogel molded product (for example, a contact lens) can be obtained by immersing in physiological saline or a storage solution for soft contact lenses.
- a solvent eg, methanol, ethanol, isopropyl alcohol, methanol aqueous solution, ethanol aqueous solution, isopropyl alcohol aqueous solution, etc.
- the moisture content of the silicone hydrogel molded product of the present invention is preferably 35% or more and less than 60%. More preferably, the moisture content is 35% or more and 55% or less, and further preferably, the moisture content is 35% or more and 50% or less.
- the hydrophilic surface of the water-containing silicone hydrogel molded article obtained by the production method of the present invention is pure water in a state where the surface of the molded article after polymerization is not subjected to post-treatment for improving the surface wettability.
- the contact angle with respect to is 60 ° or less.
- the contact angle with respect to pure water is 55 ° or less, more preferably, the contact angle with respect to pure water is 50 ° or less, and more preferably, the contact angle with respect to pure water is 45 ° or less.
- specialty post-treatment means plasma treatment, graft treatment, base treatment, acid treatment, and contact such as biocompatible LbL coating as disclosed in, for example, JP-T-2005-538767. It refers to a method for improving the wettability of the lens surface.
- the hydrophilic surface means that the contact angle is 60 ° or less when the contact angle is measured by a droplet method using pure water.
- the silicone hydrogel molded product is a silicone hydrogel soft contact lens.
- the present invention includes a silicone-containing copolymer molded article and a silicone hydrogel molded article prepared by the method of the present invention.
- Silicone hydrogel molded products include silicone hydrogel soft contact lenses.
- the present invention provides at least one monomer unit selected from the group consisting of the following (a1) and (a2), at least one monomer unit selected from the following (b), and at least one selected from the group consisting of (c1) to (c3) Silicone-containing copolymer molded article containing a monomer unit and having a hydrophilic surface with a contact angle of 60 ° or less with respect to pure water (however, the contact angle is silicone hydrous containing a silicone-containing copolymer molded article) It is the contact angle of the gel molded product).
- A1 one or more units derived from a silicone monomer containing at least one hydroxyl group and 1 to 4 silicon atoms in one molecule;
- A2) one or more silicone monomer units containing at least one polyethylene glycol group and 1 to 4 silicon atoms in one molecule;
- B) one or more units derived from a hydrophilic monomer having a vinyl group,
- C1 one or more monomer units containing two or more vinyl groups in one molecule;
- C2 one or more of monomer units containing two or more allyl groups in one molecule,
- C3 One or more monomers having two or more (meth) acrylate groups in one molecule.
- the silicone monomer (a1) can be, for example, a monomer represented by the following general formula (a1-1) or (a1-2). [Wherein R 1 , R 2 , R 3 and R 4 are methyl groups, R 5 is a hydrogen atom or a methyl group, and a represents an integer of 1 to 3. ],
- the silicone monomer (a2) can be, for example, a monomer represented by the following general formula (a2-1). [Wherein R 1 , R 2 , R 3 and R 4 are methyl groups, a represents an integer of 1 to 3, and m is 4 to 8. X in the formula is one selected from substituents represented by the following formula (Y1) or (Y2) (wherein R 5 is a hydrogen atom or a methyl group). ]
- the hydrophilic monomer (b) may be one or two selected from N-vinyl-2-pyrrolidone and N-vinyl-N-methylacetamide.
- the crosslinkable monomer (c1) is, for example, one or more selected from 1,4-butanediol divinyl ether, diethylene glycol divinyl ether, and triethylene glycol divinyl ether.
- the crosslinkable monomer (c2) is, for example, one or more selected from triallyl isocyanurate, trimethylolpropane diallyl ether, and pentaerythritol triallyl ether.
- the crosslinkable monomer (c3) includes, for example, ethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, and ethoxylated tri One or more selected from methylolpropane tri (meth) acrylate.
- the content of the silicone monomer (a1) and (a2) units is in the range of 20 to 56% by mass
- the content of the hydrophilic monomer (b) unit is in the range of 40 to 60% by mass
- the monomer The content of the units (c1), (c2) and (c3) is in the range of 0.02 to 4% by mass.
- the silicone-containing copolymer molded article is at least selected from the group consisting of a siloxane macromonomer unit, a silicone monomer unit that does not contain a hydroxyl group or a polyethylene glycol group in the molecular structure, and a monomer unit that does not contain a silicon atom in the molecular structure.
- One additional monomer unit is further contained, and the content of the additional monomer unit can be appropriately determined according to the type of the monomer.
- Each component of the silicone-containing copolymer molded article is the same as that described in the method for producing a silicone-containing copolymer molded article of the present invention.
- the hydrophilic surface of the hydrous silicone hydrogel molded product has a contact angle with pure water of 60 ° or less, and the hydrophilic surface is post-treated to improve the surface wettability of the lens-shaped material after polymerization. It was obtained without applying.
- the contact angle with pure water is a contact angle obtained by contact angle measurement by a droplet method using pure water.
- the present invention includes a silicone hydrogel soft contact lens precursor which is a silicone-containing copolymer molded article of the present invention and has a contact lens shape.
- the present invention includes a soft contact lens in which the silicone hydrogel soft contact lens precursor of the present invention is immersed in physiological saline or a soft contact lens preservation solution to be in a water-containing state.
- the moisture content of the soft contact lens in the moisture state can be, for example, 35% or more and less than 60%.
- the moisture content can be preferably 38% or more and 55% or less, more preferably 40% or more and 50% or less.
- the water contact soft contact lens of the present invention can be a soft contact lens with a replacement frequency of up to one month.
- the replacement frequency may be any number of days as long as it is within one month.
- the soft contact lens in the water-containing state of the present invention has a one-day replacement type (so-called one-day type) or a two-week type. (2 week type). However, it is not the intention limited to these.
- the present invention includes a packaged soft contact lens product in which the soft contact lens of the present invention and physiological saline or a storage solution for soft contact lens are stored in a sealed container.
- Existing storage solutions and sealed containers for soft contact lenses can be used as they are.
- 4Si-GMA (3-Methacryloxy-2-hydroxypropoxy) propyltris (trimethylsiloxy) silane [CAS: 71223-14-8]
- the relative content ratio in 4Si-GMA was 82% by mass for the structure (D3) below and 18% by mass for the structure (D4).
- (C) Crosslinkable monomer having two or more vinyl groups or allyl groups in the molecule
- TAIC triallyl isocyanurate [CAS: 1025-15-6]
- BDVE 1,4-butanediol divinyl ether [CAS: 3891-33-6]
- TEGDVE Triethylene glycol divinyl ether [CAS: 765-12-8]
- Perhexa HC 1,1-di (t-hexylperoxy) cyclohexane [NOF Corporation, CAS: 27215-08-3, 22743-71-1, 10-hour half-life temperature: 87.1 ° C.]
- Perhexyl I t-hexyl peroxyisopropyl carbonate [NOF Corporation, CAS: 132929-84-1, 10 hour half-life temperature: 95.0 ° C.]
- Siloxane Macromonomer Macromer A Siloxane Macromonomer Macromer B Obtained in Synthesis Example 3
- Siloxane Macromonomer FM-0711 Obtained in Synthesis Example 4
- Monomethacryloyl-terminated Polydimethylsiloxane JNC Corporation, Product Name: Sailor Plane FM-0711
- MCR-M07 monomethacryloyloxypropyl-terminated polydimethylsiloxane [Gelest, product code: MCR-M07, CAS: 146632-07-7]
- Synthesis example 1 Synthesis of Silicone Monomer with Repeating Number of PEG Part Only 4 A commercially available tetraethylene glycol was purchased, and the number of repeating PEG part was only 4 by column purification (Compound 1). Next, only one end of tetraethylene glycol was protected with trityl chloride (Compound 2), and the other end was allylated with allyl chloride (Compound 3). Tris (trimethylsiloxy) silane (9.34 g: 31.47 mmol) and Platinum-divinyltetramethyldisiloxane complex in xylene (300 ⁇ L) were added to compound 3 (15.0 g: 31.47 mmol), and the mixture was heated at 35 ° C. without solvent for 3 days. . After confirming disappearance of the raw material by TLC, column purification was performed to obtain Compound 4 (15.8 g).
- the measurement conditions of MALDI-TOF MS are as follows.
- Laser light source N 2 laser (wavelength: 337 nm)
- Measurement mode reflector mode, positive ion mode
- Measurement mass range m / z: 20-1500 Integration count: 1000 times
- Ionizing reagent Sodium trifluoroacetate (THF solution)
- the siloxane compound represented by E1 was reacted with methacryloyl chloride and 1,8-diazabicyclo [5.4.0] -7-undecene as a catalyst in an n-hexane solvent.
- the solution after the reaction was filtered through a glass fiber filter paper, washed with methanol and then with a saturated saline solution, dried over anhydrous sodium sulfate, purified by column, and further distilled off the solvent to remove the monomer of the following formula E2. (Hereinafter 4Si-4PEG) was obtained.
- Synthesis example 2 Synthesis of silicone monomer having only 6 PEG repeats
- Commercially available hexaethylene glycol was purchased, and the number of PEG repeats was 6 only by column purification (Compound 6).
- compound 7 trityl chloride
- compound 8 allylated with allyl chloride
- Tris (trimethylsiloxy) silane (9.34 g: 31.47 mmol) and Platinum-divinyltetramethyldisiloxane complex in xylene (300 ⁇ L) were added to compound 8 (17.8 g: 31.47 mmol), and the mixture was heated at 35 ° C. without solvent for 3 days. .
- the siloxane compound represented by E3 and 2-isocyanatoethyl methacrylate were reacted with dibutyltin dilaurate as a catalyst in a methylene chloride solvent.
- the solution after the reaction was subjected to column purification and further distillation of the solvent to obtain a monomer of the following formula E4 (hereinafter referred to as 4Si-6PEG).
- Synthesis example 3 Synthesis of Macromer A
- 35 g of both ends carbinol-modified polydimethylsiloxane (Shin-Etsu Chemical Co., Ltd., product name: KF-6001, degree of polymerization: 20, hydroxyl equivalent: 920 g / mol)
- isophorone diisocyanate 8 .29 g (37.3 mmol) and 0.03 g of dibutyltin dilaurate were added, and the mixture was stirred at 25 ° C. for 48 hours under a nitrogen stream.
- the gel permeation chromatography measurement conditions are as follows. Column: Shodex KF-402.5HQ 2 eluents: THF Flow rate: 0.3 mL / min Detector: RI Column temperature: 40 ° C
- Synthesis example 4 Synthesis of Macromer B In a 100 mL three-necked flask, 35 g of both ends carbinol-modified polydimethylsiloxane (Shin-Etsu Chemical Co., Ltd., product name: KF-6001, degree of polymerization: 20, hydroxyl equivalent: 920 g / mol), isophorone diisocyanate 8 .29 g (37.3 mmol) and 0.03 g of dibutyltin dilaurate were added, and the mixture was stirred at 25 ° C. for 48 hours under a nitrogen stream.
- carbinol-modified polydimethylsiloxane Shin-Etsu Chemical Co., Ltd., product name: KF-6001, degree of polymerization: 20, hydroxyl equivalent: 920 g / mol
- isophorone diisocyanate 8 .29 g (37.3 mmol) and 0.03 g of dibutyltin dilaurate
- Example 1 Example using a polymerization initiator having a 10-hour half-life temperature of 70 ° C. or more and 100 ° C. or less
- a 20 mL capacity brown glass bottle 1.5 g (15% by mass) of macromer A obtained in Synthesis Example 3
- 4G 0.03 g (0.3% by mass with respect to the total amount of Macromer A, 3Si-GMA, HEMA and NVP
- TEGDVE 0.03 g
- perbutyl O 0.06 g of perbutyl O (0.6% by mass with respect to the total amount of Macromer A, 3Si-GMA, HEMA and NVP
- the lens after polymerization is taken out of the mold and immersed in a 50 vol% ethanol aqueous solution for 4 hours, and then replaced with distilled water or a rinsing solution for soft contact lenses (trade name: Pure Soak S, manufactured by HOYA Corporation). I got a lens.
- the following evaluation and measurement were performed using the obtained soft contact lens. The results are shown in Table 1.
- the contact angle of the obtained contact lens was 50 ° and had a hydrophilic surface.
- the oxygen transmission coefficient was measured according to the polarographic method described in ISO 18369-4. The measurement was performed using an O2 Permometer Model 201T manufactured by Rehder Development Company. The lens thickness was plotted on the x-axis and the t / Dk value obtained by measurement was plotted on the y-axis, and the reciprocal of the slope of the regression line was defined as the oxygen transmission coefficient.
- the XPS measurement conditions are as follows. Irradiation X-ray: Al-K ⁇ Monochrome ⁇ 100 ⁇ m Photoelectron extraction angle: 45 degrees Charge neutralization: 10 V Ar ion + 20 ⁇ A Simultaneous irradiation with electron beam
- Example 2 A lens was produced in the same manner as in Example 1 except that the polymerization initiator was changed to V-40 in the monomer composition of the soft contact lens and the gelation conditions were changed to the following.
- the contact angle of the obtained contact lens was 40 ° and had a hydrophilic surface (Table 1).
- Example 3 A lens was produced in the same manner as in Example 1 except that the polymerization initiator was changed to perhexa HC in the monomer composition of the soft contact lens and the gelation conditions were changed to the following.
- the contact angle of the obtained contact lens was 33 ° and had a hydrophilic surface (Table 1).
- Example 4 A lens was produced in the same manner as in Example 1 except that the polymerization initiator was changed to perhexyl I in the monomer composition of the soft contact lens and the gelation conditions were changed to the following.
- the contact angle of the obtained contact lens was 53 ° and had a hydrophilic surface (Table 1).
- Comparative Example 1 Example using a polymerization initiator having T10 of less than 70 ° C.
- a lens was produced in the same manner as in Example 1 except that the polymerization initiator was changed to V-65 in the monomer composition of the soft contact lens.
- the surface of the obtained contact lens has a small proportion of nitrogen element that is thought to be derived from N-vinyl-2-pyrrolidone, and on the contrary, a large amount of silicon element derived from the silicone component is distributed, and the contact angle of the lens surface is 102 °. It was inferior to water wettability (Table 1).
- Comparative Example 2 Example using a polymerization initiator having T10 of less than 70 ° C.
- a lens was produced in the same manner as in Example 1 except that the polymerization initiator was changed to V-60 in the monomer composition of the soft contact lens.
- the surface of the obtained contact lens has a small proportion of nitrogen element that is thought to be derived from N-vinyl-2-pyrrolidone, and on the contrary, a large amount of silicon element derived from the silicone component is distributed, and the contact angle of the lens surface is 102 °. It was inferior to water wettability (Table 1).
- Comparative Example 3 Example using a polymerization initiator with T10 exceeding 100 ° C.
- a lens was prepared in the same manner as in Example 1 except that the polymerization initiator was changed to V-30 in the monomer composition of the soft contact lens and the gelation conditions were changed to the following.
- the obtained contact lens was brittle and could not be removed from the mold (Table 1).
- a polymerization initiator having a T10 of 70 ° C. or higher and 100 ° C. or lower is used, and the gelation conditions are maintained for at least 1 hour within a temperature range from T10 of the polymerization initiator to 35 ° C. lower than T10 (P1 step). ), And the curing conditions were maintained at a temperature higher than T10 of the polymerization initiator for 1 hour or more (step P2)
- the amount of silicon element derived from the silicone component on the contact lens surface can be reduced. It was possible to obtain a contact lens having a hydrophilic surface without any post-treatment after polymerization.
- Example 5 Example using a polymerization initiator having T10 of 70 ° C. or more and 100 ° C. or less
- 1.5 g (15% by mass) of Macromer B obtained in Synthesis Example 4 is 2.5 g (25% by mass) of 3Si-GMA, and 0.8 g (8% by mass) of FM-0711.
- This monomer mixture was poured into a double-sided cast mold for making a contact lens made of polypropylene, and the upper mold and the lower mold were assembled and then placed in a pressure polymerization furnace. After the polymerization furnace was purged with nitrogen for 20 minutes, under the conditions of 0.2 kgf / cm 2, and polymerized by a polymerization schedule shown below.
- the lens after polymerization is taken out of the mold and immersed in a 50 vol% ethanol aqueous solution for 4 hours, and then replaced with distilled water or a rinsing solution for soft contact lenses (trade name: Pure Soak S, manufactured by HOYA Corporation). I got a lens.
- the results are shown in Table 2.
- the contact angle of the obtained contact lens was 48 ° and had a hydrophilic surface.
- Example 6 A lens was produced in the same manner as in Example 5 except that the polymerization initiator was changed to V-40 in the monomer composition of the soft contact lens and the gelation conditions were changed to the following.
- the contact angle of the obtained contact lens was 40 ° and had a hydrophilic surface (Table 2).
- Example 7 A lens was prepared in the same manner as in Example 6 except that the polymerization initiator was changed to perhexa HC in the monomer composition of the soft contact lens and the gelation conditions were changed to the following.
- the contact angle of the obtained contact lens was 32 ° and had a hydrophilic surface (Table 2).
- Example 8 A lens was produced in the same manner as in Example 5 except that the polymerization initiator was changed to perhexyl I in the monomer composition of the soft contact lens and the gelation conditions were changed to the following.
- the contact angle of the obtained contact lens was 44 ° and had a hydrophilic surface (Table 2).
- Comparative Example 4 Example using a polymerization initiator having T10 of less than 70 ° C.
- a lens was produced in the same manner as in Example 5 except that the polymerization initiator was changed to V-65 in the monomer composition of the soft contact lens.
- the obtained contact lens was not circular but distorted, and was not suitable as a contact lens (Table 2).
- Comparative Example 5 Example using a polymerization initiator having T10 of less than 70 ° C.
- a lens was produced in the same manner as in Example 5 except that the polymerization initiator was changed to V-60 in the monomer composition of the soft contact lens.
- the obtained contact lens was not circular but distorted, and was not suitable as a contact lens (Table 2).
- Comparative Example 6 Example using a polymerization initiator with T10 exceeding 100 ° C.
- a lens was prepared in the same manner as in Example 5 except that the polymerization initiator was changed to V-30 in the monomer composition of the soft contact lens and the gelation conditions were changed to the following.
- the obtained contact lens was brittle and could not be removed from the mold (Table 2).
- a polymerization initiator having a T10 of 70 ° C. or more and 100 ° C. or less is used, and the gelation conditions are maintained for at least 1 hour within a temperature range from T10 of the polymerization initiator to 35 ° C. lower than T10 (P1 Step 5) and curing conditions were maintained at a temperature higher than T10 of the polymerization initiator for 1 hour or longer (Step P2).
- contact lenses having a hydrophilic surface were obtained without any post-treatment after polymerization. I was able to get it.
- the lens was deformed and was not suitable as a contact lens. Furthermore, in Comparative Example 6 using a polymerization initiator having a T10 exceeding 100 ° C., the lens after polymerization was brittle, and the lens could not be taken out from the mold.
- Examples 9 to 12 and Comparative Examples 7 to 8 (when the structure of the silicone monomer is changed variously by using a polymerization initiator having T10 of 70 ° C. or more and 100 ° C. or less)
- a monomer mixture was prepared with the composition shown in Table 3, and lenses were produced in the same manner as in Example 1.
- Gelling conditions and curing conditions were as follows.
- Examples 13-20 A lens was produced in the same manner as in Example 1 except that a monomer mixed solution was prepared with the composition shown in Table 4.
- the gelation conditions and cure conditions were all as follows.
- Comparative Example 9 A lens was produced in the same manner as in Example 13 except that the monomer mixture was prepared with the composition shown in Table 4. The obtained lens was inferior in surface water wettability because it contained N, N-dimethylacrylamide as a component of the lens.
- Comparative Example 10 A monomer mixed solution was prepared with the composition shown in Table 4, and the monomer mixed solution was poured into a double-sided cast mold for making a contact lens made of polypropylene, and an upper mold and a lower mold were assembled. The mold was irradiated with light having an irradiation intensity of 11 mW / cm 2 in the 280 to 390 nm region for 20 minutes to complete the polymerization. The obtained lens was inferior in surface water wettability.
- Comparative Example 11 A monomer mixed solution having the same composition as in Example 20 was prepared, and this monomer mixed solution was poured into a double-sided cast mold for making a contact lens made of polypropylene. After the upper mold and the lower mold were assembled, they were placed in a pressure polymerization furnace. I put it in. After replacing the inside of the polymerization furnace with nitrogen for 30 minutes, polymerization was carried out under the condition of 0.2 kgf / cm 2 according to the polymerization schedule shown below.
- the lens after polymerization is taken out of the mold and immersed in a 50 vol% ethanol aqueous solution for 4 hours, and then replaced with distilled water or a rinsing solution for soft contact lenses (trade name: Pure Soak S, manufactured by HOYA Corporation). I got a lens.
- the obtained contact lens was not circular but was distorted and was not suitable as a contact lens.
- Comparative Example 12 A monomer mixed solution having the same composition as in Example 20 was prepared, and a lens was produced in the same manner as in Comparative Example 11 except that the gelation conditions were changed to the following. The obtained contact lens was brittle and could not be removed from the mold.
- a polymerization initiator having a T10 of 70 ° C. or more and 100 ° C. or less is used, and the gelation conditions are maintained for at least 1 hour within a temperature range from T10 of the polymerization initiator to 35 ° C. lower than T10 (P1 Step 13), and curing conditions were maintained at a temperature higher than T10 of the polymerization initiator for 1 hour or longer (Step P2).
- the silicone hydrogel having a hydrophilic surface without any post-treatment after polymerization I got a contact lens.
- Comparative Example 9 containing N, N-dimethylacrylamide as a monomer component is a lens having poor surface water wettability, and is suitable as a contact lens without post-polymerization after-treatment. It wasn't.
- Comparative Example 10 employing the photopolymerization method the lens was inferior in water wettability on the surface and was not suitable as a contact lens without post-treatment after polymerization.
- Comparative Example 11 in which the maintenance time under the curing conditions corresponding to the P2 step is less than 1 hour, the lens is deformed and contact It was not suitable as a lens. Furthermore, even if it maintained for 1 hour or more in the temperature range 35 degreeC lower than T10 from T10, in the comparative example 12 which does not pass P2 process, the lens after superposition
- the present invention is useful in the field related to contact lenses.
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Abstract
Description
疎水性キャビティ表面を有するモールド型のキャビティにおいて、
(a)少なくとも1種の(メタ)アクリロイル基を有するシリコーンモノマー、(b)少なくとも1種のビニル基を有する親水性モノマー、(c)少なくとも1種の架橋性モノマー及び(d)少なくとも1種の重合開始剤を含有するモノマー溶液を重合して、
親水性表面を有する、シリコーンモノマー単位、親水性モノマー単位及び架橋性モノマー単位を含有するシリコーン含有共重合体成形品を作製する方法であって、
前記重合開始剤は、10時間半減期温度(以下、T10と略記する)が70℃以上、100℃以下であり、
前記重合を、前記モノマー溶液に含有される重合開始剤のT10からT10より35℃低い温度の範囲内で1時間又はそれ以上維持するP1工程、及び前記モノマー溶液に含有される重合開始剤のT10より高い温度で1時間又はそれ以上維持するP2工程で行う、前記方法。
[2]
前記P1工程における維持温度が、前記T10より10℃低い温度からT10より35℃低い温度の範囲である[1]に記載の方法。
[3]
P2工程における維持温度が、前記T10より5℃高い温度からT10より50℃高い温度の範囲である[1]又は[2]に記載の方法。
[4]
前記重合開始剤が、アゾ重合開始剤又は有機過酸化物重合開始剤である[1]~[3]のいずれか1項に記載の方法。
[5]
前記シリコーン含有共重合体成形品の前記シリコーンモノマー(a)単位の含有量が20~56質量%の範囲であり、前記親水性モノマー(b)単位の含有量が40~60質量%の範囲であり、前記架橋性モノマー(c)単位の含有量が0.02~4質量%の範囲である[1]~[4]のいずれか1項に記載の方法。
[6]
前記シリコーンモノマー(a)が下記(a1)及び(a2)から成る群から選ばれる少なくとも1種のモノマーである[1]~[5]のいずれか1項に記載の方法。
(a1)少なくとも1つの水酸基及び1個~4個のケイ素原子を1分子中に含有するシリコーンモノマーの1種又は2種以上、
(a2)少なくとも1つのポリエチレングリコール基及び1個~4個のケイ素原子を1分子中に含有するシリコーンモノマーの1種又は2種以上。
[7]
前記シリコーンモノマー(a1)が、下記一般式(a1-1)又は(a1-2)で示されるモノマーであり、
前記シリコーンモノマー(a2)が、下記一般式(a2-1)で示されるモノマーである、[6]に記載の方法。
前記親水性モノマー(b)が、N-ビニル-2-ピロリドン及びN-ビニル-N-メチルアセトアミドから選択される1種又は2種である、[1]~[7]のいずれか1項に記載の方法。
[9]
前記架橋性モノマー(c)が、(c1)、(c2)及び(c3)から成る群から選ばれる少なくとも1種のモノマーである[1]~[8]のいずれか1項に記載の方法。
(c1)1分子中に2つ以上のビニル基を含有するモノマーの1種又は2種以上、
(c2)1分子中に2つ以上のアリル基を含有するモノマーの1種又は2種以上、
(c3)1分子中に2つ以上の(メタ)アクリレート基を有するモノマーの1種又は2種以上。
[10]
前記モノマー(c1)が、1,4-ブタンジオールジビニルエーテル、ジエチレングリコールジビニルエーテル、及びトリエチレングリコールジビニルエーテルから選択される1種又は2種以上であり、
前記モノマー(c2)が、トリアリルイソシアヌレート、トリメチロールプロパンジアリルエーテル、及びペンタエリスリトールトリアリルエーテルから選択される1種又は2種以上であり、
前記モノマー(c3)が、エチレングリコールジ(メタ)アクリレート、トリエチレングリコールジ(メタ)アクリレート、テトラエチレングリコールジ(メタ)アクリレート、トリメチロールプロパントリ(メタ)アクリレート、及びエトキシ化トリメチロールプロパントリ(メタ)アクリレートから選ばれる1種又は2種以上のモノマーである[9]に記載の方法。
[11]
前記モノマー溶液は、シロキサンマクロモノマー、分子構造中に水酸基またはポリエチレングリコール基を含まないシリコーンモノマー、及び分子構造中にケイ素原子を含まないモノマーから成る群から選ばれる少なくとも1種の補助モノマーをさらに含有する[1]~[10]のいずれか1項に記載の方法。
[12]
前記シリコーン含有共重合体成形品の親水性表面は、重合後の成形品表面に表面の水濡れ性を良化させるための後処理を施さない状態で、純水に対する接触角が60°以下である(但し、前記接触角はシリコーン含有共重合体成形品を含水させたシリコーンハイドロゲル成形品の接触角である)[1]~[11]のいずれか1項に記載の方法。
[13]
疎水性キャビティ表面を有するモールド型がポリアルキレン製コンタクトレンズ成形用両面キャストモールドであり、前記シリコーン含有共重合体成形品が、シリコーンハイドロゲルソフトコンタクトレンズ用前駆体である[1]~[12]のいずれか1項に記載の方法。
[14]
[1]~[13]のいずれか1項に記載の方法で調製されたシリコーン含有共重合体成形品。
[15]
下記(a1)及び(a2)から成る群から選ばれる少なくとも1種のモノマー単位、下記(b)のモノマー単位、及び(c1)~(c3)から成る群から選ばれる少なくとも1種のモノマー単位からなり(但し、(g)分子構造中にケイ素原子を含まないモノマー単位をさらに含むことができ、(g)分子構造中にケイ素原子を含まないモノマーは、2-ヒドロキシエチル(メタ)アクリレート、メタクリル酸、メチル(メタ)アクリレート、エチル(メタ)アクリレート、n-ブチル(メタ)アクリレート、2-メトキシエチル(メタ)アクリレート、2-メタクリロイルオキシエチルホスホリルコリンなどから選らばれる1種以上のモノマーである)、純水に対する接触角が60°以下である親水性表面を有する(但し、接触角はシリコーン含有共重合体成形品を含水させたシリコーンハイドロゲル成形品の接触角である)シリコーン含有共重合体成形品であって、前記シリコーンモノマー(a1)~(a2)単位の含有量が20~56質量%の範囲であり、前記モノマー(b)単位の含有量が40~60質量%の範囲であり、前記モノマー(c1)~(c3)単位の含有量が0.02~4質量%の範囲であり、かつ前記(g)分子構造中にケイ素原子を含まないモノマー単位の含有量が10質量%未満の範囲である、前記シリコーン含有共重合体成形品。
(a1)少なくとも1つの水酸基及び1個~4個のケイ素原子を1分子中に含有し、分子量が900未満であるシリコーンモノマーに由来する単位の1種又は2種以上、
(a2)少なくとも1つのポリエチレングリコール基及び1個~4個のケイ素原子を1分子中に含有し、分子量が900未満であるシリコーンモノマー単位の1種又は2種以上、
(b)ビニル基を有する親水性モノマーに由来する単位の1種又は2種以上、
(c1)1分子中に2つ以上のビニル基を含有するモノマー単位の1種又は2種以上、
(c2)1分子中に2つ以上のアリル基を含有するモノマー単位の1種又は2種以上、
(c3)1分子中に2つ以上の(メタ)アクリレート基を有するモノマーの1種又は2種以上。
[16]
下記(a1)及び(a2)から成る群から選ばれる少なくとも1種のモノマー単位、下記(b)のモノマー単位、(c1)~(c3)から成る群から選ばれる少なくとも1種のモノマー単位、及び(e)のシロキサンマクロモノマー単位を含有し、純水に対する接触角が60°以下である親水性表面を有し、かつ含水率が35%以上、60%未満である(但し、接触角及び含水率は、それぞれシリコーン含有共重合体成形品を含水させたシリコーンハイドロゲル成形品の接触角及び含水率である)シリコーン含有共重合体成形品。
(a1)少なくとも1つの水酸基及び1個~4個のケイ素原子を1分子中に含有し、分子量が900未満であるシリコーンモノマーに由来する単位の1種又は2種以上、
(a2)少なくとも1つのポリエチレングリコール基及び1個~4個のケイ素原子を1分子中に含有し、分子量が900未満であるシリコーンモノマー単位の1種又は2種以上、
(b)ビニル基を有する親水性モノマーに由来する単位の1種又は2種以上、
(c1)1分子中に2つ以上のビニル基を含有するモノマー単位の1種又は2種以上、
(c2)1分子中に2つ以上のアリル基を含有するモノマー単位の1種又は2種以上、
(c3)1分子中に2つ以上の(メタ)アクリレート基を有するモノマーの1種又は2種以上
(e)一般式(C1)および(C2)のマクロモノマーの1種又は2種以上
[17]
rは0~8であり、pは8~50であり、qは9~13であり、tは0~2である[16]に記載のシリコーン含有共重合体成形品。
[18]
(e)のシロキサンマクロモノマー単位は下記(E5)または(E6)である[16]に記載のシリコーン含有共重合体成形品。
マクロマーA
前記シリコーンモノマー(a1)が、下記一般式(a1-1)又は(a1-2)で示されるモノマーであり、
前記シリコーンモノマー(a2)が、下記一般式(a2-1)で示されるモノマーである、[15]~[18]のいずれか1項に記載のシリコーン含有共重合体成形品。
前記親水性モノマー(b)が、N-ビニル-2-ピロリドン及びN-ビニル-N-メチルアセトアミドから選択される1種又は2種である、[15]~[19]のいずれか1項に記載のシリコーン含有共重合体成形品。
[21]
前記モノマー(c1)が、1,4-ブタンジオールジビニルエーテル、ジエチレングリコールジビニルエーテル、及びトリエチレングリコールジビニルエーテルから選択される1種又は2種以上であり、
前記モノマー(c2)が、トリアリルイソシアヌレート、トリメチロールプロパンジアリルエーテル、及びペンタエリスリトールトリアリルエーテルから選択される1種又は2種以上であり、かつ
前記モノマー(c3)が、エチレングリコールジ(メタ)アクリレート、トリエチレングリコールジ(メタ)アクリレート、テトラエチレングリコールジ(メタ)アクリレート、トリメチロールプロパントリ(メタ)アクリレート、及びエトキシ化トリメチロールプロパントリ(メタ)アクリレートから選ばれる1種又は2種以上のモノマーである[15]~[20]のいずれか1項に記載のシリコーン含有共重合体成形品。
[22]
前記シリコーンモノマー(a1)及び(a2)単位の含有量が20~56質量%の範囲であり、前記モノマー(b)単位の含有量が40~60質量%の範囲であり、かつ前記モノマー(c1)、(c2)及び(c3)単位の含有量が0.02~4質量%の範囲である[16]~[21]のいずれか1項に記載のシリコーン含有共重合体成形品。
[23]
前記(e)のシロキサンマクロモノマー単位の含有量が25質量%以下である[16]~[22]のいずれか1項に記載のシリコーン含有共重合体成形品。
[24]
前記シリコーン含有共重合体成形品は、分子構造中に水酸基またはポリエチレングリコール基を含まないシリコーンモノマー単位、及び分子構造中にケイ素原子を含まないモノマー単位から成る群から選ばれる少なくとも1種の追加モノマー単位をさらに含有する[16]~[23]のいずれか1項に記載のシリコーン含有共重合体成形品。
[25]
純水に対する接触角が60°以下である親水性表面は、重合後のレンズ形状材料に表面の水濡れ性を良化させるための後処理を施すことなく得られたものである、(但し、前記接触角はシリコーン含有共重合体成形品を含水させたシリコーンハイドロゲル成形品の接触角である)[15]~[24]のいずれか1項に記載のシリコーン含有共重合体物品。
[26]
[14]~[25]のいずれか1項に記載のシリコーン含有共重合体成形品であり、かつコンタクトレンズ形状を有する、シリコーンハイドロゲルソフトコンタクトレンズ用前駆体。
[27]
[26]に記載のシリコーンハイドロゲルソフトコンタクトレンズ前駆体を生理食塩水またはソフトコンタクトレンズ用保存液にて含水状態にしたシリコーンハイドロゲルソフトコンタクトレンズ。
[28]
前記含水状態にしたシリコーンハイドロゲルソフトコンタクトレンズは含水率が35%以上、60%未満である[27]に記載のソフトコンタクトレンズ。
[29]
前記含水状態にしたシリコーンハイドロゲルソフトコンタクトレンズは、交換頻度が最長1ヶ月までのソフトコンタクトレンズである[27]又は[28]に記載のソフトコンタクトレンズ。
[30]
前記含水状態にしたシリコーンハイドロゲルソフトコンタクトレンズは、交換頻度が1日または2週間のタイプである[29]に記載のソフトコンタクトレンズ。
[31]
[27]~[30]のいずれか1項に記載のソフトコンタクトレンズ及び生理食塩水またはソフトコンタクトレンズ用保存液を密閉容器に格納した、パッケージ入りソフトコンタクトレンズ製品。
[015]
下記(a1)及び(a2)から成る群から選ばれる少なくとも1種のモノマー単位、下記(b)のモノマー単位、及び(c1)~(c3)から成る群から選ばれる少なくとも1種のモノマー単位を含有し、純水に対する接触角が60°以下である親水性表面を有する(但し、接触角はシリコーン含有共重合体成形品を含水させたシリコーンハイドロゲル成形品の接触角である)シリコーン含有共重合体成形品。
(a1)少なくとも1つの水酸基及び1個~4個のケイ素原子を1分子中に含有するシリコーンモノマーに由来する単位の1種又は2種以上、
(a2)少なくとも1つのポリエチレングリコール基及び1個~4個のケイ素原子を1分子中に含有するシリコーンモノマー単位の1種又は2種以上、
(b)ビニル基を有する親水性モノマーに由来する単位の1種又は2種以上、
(c1)1分子中に2つ以上のビニル基を含有するモノマー単位の1種又は2種以上、
(c2)1分子中に2つ以上のアリル基を含有するモノマー単位の1種又は2種以上、
(c3)1分子中に2つ以上の(メタ)アクリレート基を有するモノマーの1種又は2種以上。
[016]
前記シリコーンモノマー(a1)が、下記一般式(a1-1)又は(a1-2)で示されるモノマーであり、
前記シリコーンモノマー(a2)が、下記一般式(a2-1)で示されるモノマーである、[015]に記載のシリコーン含有共重合体成形品。
前記親水性モノマー(b)が、N-ビニル-2-ピロリドン及びN-ビニル-N-メチルアセトアミドから選択される1種又は2種である、[015]又は[016]に記載のシリコーン含有共重合体成形品。
[018]
前記モノマー(c1)が、1,4-ブタンジオールジビニルエーテル、ジエチレングリコールジビニルエーテル、及びトリエチレングリコールジビニルエーテルから選択される1種又は2種以上であり、
前記モノマー(c2)が、トリアリルイソシアヌレート、トリメチロールプロパンジアリルエーテル、及びペンタエリスリトールトリアリルエーテルから選択される1種又は2種以上であり、かつ
前記モノマー(c3)が、エチレングリコールジ(メタ)アクリレート、トリエチレングリコールジ(メタ)アクリレート、テトラエチレングリコールジ(メタ)アクリレート、トリメチロールプロパントリ(メタ)アクリレート、及びエトキシ化トリメチロールプロパントリ(メタ)アクリレートから選ばれる1種又は2種以上のモノマーである[015]~[017]のいずれか1項に記載のシリコーン含有共重合体成形品。
[019]
前記シリコーンモノマー(a1)及び(a2)単位の含有量が20~56質量%の範囲であり、前記親水性モノマー(b)単位の含有量が40~60質量%の範囲であり、かつ前記モノマー(c1)、(c2)及び(c3)単位の含有量が0.02~4質量%の範囲である[015]~[018]のいずれか1項に記載のシリコーン含有共重合体成形品。
[020]
前記シリコーン含有共重合体成形品は、シロキサンマクロモノマー単位、分子構造中に水酸基またはポリエチレングリコール基を含まないシリコーンモノマー単位、及び分子構造中にケイ素原子を含まないモノマー単位から成る群から選ばれる少なくとも1種の追加モノマー単位をさらに含有する[015]~[019]のいずれか1項に記載のシリコーン含有共重合体成形品。
[021]
純水に対する接触角が60°以下である親水性表面は、重合後のレンズ形状材料に表面の水濡れ性を良化させるための後処理を施すことなく得られたものである、(但し、前記接触角はシリコーン含有共重合体成形品を含水させたシリコーンハイドロゲル成形品の接触角である)[015]~[020]のいずれか1項に記載のシリコーン含有共重合体物品。
[022]
[14]、[015]~[021]のいずれか1項に記載のシリコーン含有共重合体成形品であり、かつコンタクトレンズ形状を有する、シリコーンハイドロゲルソフトコンタクトレンズ用前駆体。
[023]
[022]に記載のシリコーンハイドロゲルソフトコンタクトレンズ前駆体を生理食塩水またはソフトコンタクトレンズ用保存液にて含水状態にしたシリコーンハイドロゲルソフトコンタクトレンズ。
[024]
前記含水状態にしたシリコーンハイドロゲルソフトコンタクトレンズは含水率が35%以上、60%未満である[023]に記載のソフトコンタクトレンズ。
[025]
前記含水状態にしたシリコーンハイドロゲルソフトコンタクトレンズは、交換頻度が最長1ヶ月までのソフトコンタクトレンズである[023]又は[024]に記載のソフトコンタクトレンズ。
[026]
前記含水状態にしたシリコーンハイドロゲルソフトコンタクトレンズは、交換頻度が1日または2週間のタイプである[025]に記載のソフトコンタクトレンズ。
[027]
[023]~[026]のいずれか1項に記載のソフトコンタクトレンズ及び生理食塩水またはソフトコンタクトレンズ用保存液を密閉容器に格納した、パッケージ入りソフトコンタクトレンズ製品。
本発明の親水性表面を有するシリコーン含有共重合体成形品を作製する方法は、疎水性キャビティ表面を有するモールド型のキャビティにおいて、
(a)少なくとも1種のシリコーンモノマー、(b)少なくとも1種のビニル基を有する親水性モノマー、(c)少なくとも1種の架橋性モノマー及び(d)少なくとも1種の重合開始剤を含有するモノマー溶液を重合して、
親水性表面を有する、シリコーンモノマー単位、親水性モノマー単位及び架橋性モノマー単位を含有するシリコーン含有共重合体成形品を作製する方法である。ここで、前記重合開始剤は、10時間半減期温度(T10)が70℃以上、100℃以下である。さらに、前記重合は、前記モノマー溶液に含有される重合開始剤のT10からT10より35℃低い温度の範囲内で少なくとも1時間維持するP1工程、及び前記モノマー溶液に含有される重合開始剤のT10より高い温度で1時間以上維持するP2工程を含む。
本発明の方法で用いるモールド型は、疎水性キャビティ表面を有するモールド型である。疎水性キャビティ表面の疎水性は、例えば、純水に対する接触角が90°以上であることを意味する。キャビティ表面の疎水性はキャビティ表面またはモールド型の材料に起因して生じる疎水性を意味し、特別な疎水性付与処理をすることを要しない。但し、重合後の剥離性等を考慮して、キャビティ表面に対して特別な疎水性付与処理をしたものを排除する意図ではない。また、疎水性キャビティ表面の純水に対する接触角の上限に制限はないが、一般に120°である。但し、この角度に限定される意図ではない。
モノマー溶液は、(a)少なくとも1種の(メタ)アクリロイル基を有するシリコーンモノマー、(b)少なくとも1種のビニル基を有する親水性モノマー、(c)少なくとも1種の架橋性モノマー及び(d)少なくとも1種の重合開始剤を含有する。
シリコーンモノマー(a)は、(メタ)アクリロイル基を有するシリコーンモノマーである。シリコーンモノマー(a)は、1分子に1個の(メタ)アクリロイル基を有する。本願明細書において、(メタ)アクリロイル基は、メタクリロイル基及びアクリロイル基のいずれかを意味する。本願明細書においてシリコーンモノマーは、分子量が900未満であることが適当である。理由は後述する。
シリコーンモノマー(a)は、1個~4個のケイ素原子を1分子中に含有し、かつ分子中に少なくとも1つの水酸基又はポリエチレングリコール基を有しているシリコーンモノマーであることが好ましい。分子中に少なくとも1つの水酸基又はポリエチレングリコール基を有しているシリコーンモノマーを用いることで、親水性に優れたシリコーン含有共重合体成形品を得ることができる。そのようなシリコーンモノマーは、例えば、下記(a1)又は(a2)のシリコーンモノマーであることができる。
(a1)少なくとも1つの水酸基及び1個~4個のケイ素原子を1分子中に含有するシリコーンモノマーの1種又は2種以上、
(a2)少なくとも1つのポリエチレングリコール基及び1個~4個のケイ素原子を1分子中に含有するシリコーンモノマーの1種又は2種以上
親水性モノマーは、ビニル基を有する親水性モノマーである。ビニル基を有する親水性モノマーを用いることで、最終的に得られるレンズ表面の水濡れ性を高めることが可能となる。ビニル基を有する親水性モノマーは、例えば、N-ビニル-2-ピロリドン及びN-ビニル-N-メチルアセトアミドから選択される1種又は2種であることができる。
架橋性モノマーは、ビニル基を有する親水性モノマー又は(メタ)アクリレート基を有するモノマーを架橋し、共重合体に耐熱性および耐溶剤性を付与することができる。モノマー溶液中の前記架橋性モノマーの含有量は、全モノマーの合計量に対して0.02~4質量%の範囲であることが適当である。
(c1)1分子中に2つ以上のビニル基を含有するモノマーの1種又は2種以上、
(c2)1分子中に2つ以上のアリル基を含有するモノマーの1種又は2種以上、
(c3)1分子中に2つ以上の(メタ)アクリレート基を有するモノマーの1種又は2種以上。尚、本願明細書において、「(メタ)アクリレート基」はアクリレート基又はメタクリレート基を意味する。
架橋性モノマー(c3)の含有量は、全モノマーの合計量に対し0.1~3質量%であることが好ましい。架橋性モノマー(c3)の使用量が0.1質量%以上で機械的強度と耐久性の付与が認められ、また3質量%以下とすることで、得られるソフトコンタクトレンズが脆くなることを防止することが出来る。架橋性モノマー(c3)の含有量は、より好ましくは0.2~2質量%である。
架橋性モノマー(c1)、(c2)及び(c3)は、単独で使用しても、組み合わせて使用しても良く、組合せて使用する場合の含有量の合計量は、0.02~4質量%の範囲である。
重合開始剤は、10時間半減期温度(T10)が70℃以上、100℃以下である。上記T10範囲の重合開始剤を用いることで、(a)、(b)及び(c)のモノマーを含有するモノマー溶液から、後に詳述するP1工程(重合開始剤のT10からT10より35℃低い温度の範囲内で1時間又はそれ以上維持)及びP2工程(重合開始剤のT10より高い温度で1時間又はそれ以上維持)の2段階の重合工程を経ることで、本発明の目的とする親水性表面を有するシリコーン含有共重合体成形品を得ることができる。
(d1)1,1’-アゾビス(シクロヘキサン-1-カルボニトリル)[和光純薬工業株式会社、CAS:2094-98-6、T10:88℃(トルエン中)]、
(d2)t-ブチルパーオキシ-2-エチルヘキサノエート[日油株式会社、商品名:パーブチルO、CAS:3006-82-4、T10:72.1℃(ベンゼン中)]、
(d3)1,1-ジ(t-ヘキシルパーオキシ)-3,3,5-トリメチルシクロヘキサン[日油株式会社、商品名:パーヘキサTMH、CAS:104066-39-9、T10:86.7℃(ベンゼン中)]、
(d4)1,1-ジ(t-ヘキシルパーオキシ)シクロヘキサン[日油株式会社、商品名:パーヘキサHC、CAS:27215-08-3、22743-71-1、T10:87.1℃(ベンゼン中)]、
(d5)t-ヘキシルパーオキシイソプロピルカーボネート[日油株式会社、商品名:パーヘキシルI、CAS:132929-84-1、T10:95.0℃(ベンゼン中)]、
(d6)t-ブチルパーオキシ-3,5,5-トリメチルヘキサノエート[日油株式会社、商品名:パーブチル355、CAS:13122-18-4、T10:97.1℃(ベンゼン中)]、
(d7)t-ブチルパーオキシラウレート[日油株式会社、商品名:パーブチルL、CAS:2123-88-8、T10:98.3℃(ベンゼン中)]。
(a1)少なくとも1つの水酸基及び1個~4個のケイ素原子を1分子中に含有するシリコーンモノマーの1種又は2種以上、
(a2)少なくとも1つのポリエチレングリコール基及び1個~4個のケイ素原子を1分子中に含有するシリコーンモノマーの1種又は2種以上、
(b)ビニル基を有する親水性モノマーの1種又は2種以上、
(c1)1分子中に2つ以上のビニル基を含有するモノマーの1種又は2種以上、
(c2)1分子中に2つ以上のアリル基を含有するモノマーの1種又は2種以上
(c3)1分子中に2つ以上の(メタ)アクリレート基を有するモノマーの1種又は2種以上。
モノマー溶液を、疎水性キャビティ表面を有するモールド型のキャビティにおいて重合する。重合は、前記モノマー溶液に含有される重合開始剤のT10からT10より35℃低い温度の範囲内で少なくとも1時間維持するP1工程、及び前記モノマー溶液に含有される重合開始剤のT10より高い温度で1時間以上維持するP2工程で行う。尚、本明細書では、P1工程における重合を「ゲル化」と言い、P2工程における重合を「キュア」と言う場合がある。
モノマー溶液に含有される重合開始剤のT10からT10より35℃低い温度の範囲内で少なくとも1時間維持する。P1工程における維持温度は、好ましくはT10より10℃低い温度からT10より35℃低い温度の範囲であり、より好ましくはT10より15℃低い温度からT10より35℃低い温度の範囲であり、さらに好ましくはT10より20℃低い温度からT10より35℃低い温度の範囲である。
P1工程の後に、モノマー溶液に含有される重合開始剤のT10より高い温度で1時間以上維持するP2工程で行う。P2工程における維持温度は、好ましくはT10より5℃高い温度からT10より50℃高い温度の範囲であり、より好ましくはT10より10℃高い温度からT10より50℃高い温度の範囲であり、さらに好ましくはT10より15℃高い温度からT10より50℃高い温度の範囲である。
P1工程における保持時間は、好ましくは5時間以上、14時間以下である。保持時間を5時間以上とすることで、その後キュアへと移行したときに良好な親水性表面が得られ易く、かつレンズ形状に重合した場合、膨潤後に円形状のレンズが得られ易いからである。但し、14時間を超える場合には、総重合時間(「ゲル化」と「キュア」をあわせた時間)が長くなり過ぎることで生産効率が悪くなるため、14時間以下とすることが好ましい。この「ゲル化」の保持時間は、より好ましくは6時間~12時間である。尚、維持時間(保持時間も同義)は、P1工程における維持(保持)温度までの昇温時間は含まない時間を意味し、維持(保持)温度範囲内での昇温時間は、維持時間(保持時間も同義)に含むものとする。同様に、P1工程における維持(保持)温度から、P2工程における維持(保持)温度までの昇温時間は含まない時間を意味し、維持(保持)温度範囲内での昇温時間は、維持時間(保持時間も同義)に含むものとする。
尚、P1工程及びP2工程のいずれにおいても、温度の維持は、各工程中変更することなく行うこともできるが、各工程中に、所定の範囲内で、変動させることもできる。例えば、P1工程については、重合開始剤のT10からT10より35℃低い温度の範囲内において、段階的に温度を上昇させることができる。より具体的には、例えば、(i)T10より30℃低い温度で、ある時間t1維持し、その後、(ii)T10より20℃低い温度で、さらにある時間t2維持することができる。この場合、P1工程における1時間以上の維持時間は、(i)での加熱開始から、(i)から(ii)への昇温時間を含む(ii)での加熱終了までの時間を意味する。同様に、P2工程においても、重合開始剤のT10より高い温度において、段階的に温度を上昇させることができる。より具体的には、例えば、(iii)T10より10℃高い温度で、ある時間t1維持し、その後、(iv)T10より20℃高い温度で、さらにある時間t2維持することができる。この場合、P2工程における1時間以上の維持時間は、(iii)での加熱開始から、(iii)から(iv)への昇温時間を含む(iv)での加熱終了までの時間を意味する。P2工程においては、より具体的には、段階的に最高温度130℃以下まで昇温し、さらに例えば、4時間~10時間加熱して重合を完結させることができる。P1工程及びP2工程における重合スケジュール(設定温度及び時間)は、上記例に限定される意図はなく、適宜選択できる。
本発明は、前記本発明の方法で調製されたシリコーン含有共重合体成形品及びシリコーンハイドロゲル成形品を包含する。シリコーンハイドロゲル成形品には、シリコーンハイドロゲルソフトコンタクトレンズが含まれる。
(a1)少なくとも1つの水酸基及び1個~4個のケイ素原子を1分子中に含有するシリコーンモノマーに由来する単位の1種又は2種以上、
(a2)少なくとも1つのポリエチレングリコール基及び1個~4個のケイ素原子を1分子中に含有するシリコーンモノマー単位の1種又は2種以上、
(b)ビニル基を有する親水性モノマーに由来する単位の1種又は2種以上、
(c1)1分子中に2つ以上のビニル基を含有するモノマー単位の1種又は2種以上、
(c2)1分子中に2つ以上のアリル基を含有するモノマー単位の1種又は2種以上、
(c3)1分子中に2つ以上の(メタ)アクリレート基を有するモノマーの1種又は2種以上。
本発明は、上記本発明のシリコーン含有共重合体成形品であり、かつコンタクトレンズ形状を有する、シリコーンハイドロゲルソフトコンタクトレンズ用前駆体を包含する。
本発明は、上記本発明のシリコーンハイドロゲルソフトコンタクトレンズ用前駆体を生理食塩水またはソフトコンタクトレンズ用保存液に浸漬して含水状態にしたソフトコンタクトレンズを包含する。
本発明は、前記本発明のソフトコンタクトレンズ及び生理食塩水またはソフトコンタクトレンズ用保存液を密閉容器に格納した、パッケージ入りソフトコンタクトレンズ製品を包含する。ソフトコンタクトレンズ用保存液及び密閉容器は、既存のものをそのまま利用できる。
以下の実施例および比較例で用いられている化学物質の名称と略語を示す。
(a)分子構造中に少なくとも1つの水酸基またはポリエチレングリコール基を有するシリコーンモノマー
3Si-GMA:(3-メタクリルオキシ-2-ヒドロキシプロポキシ)プロピルビス(トリメチルシロキシ)メチルシラン[CAS:69861-02-5]
3Si-GMA中の相対含有比は、下記(D1)の構造が75質量%で(D2)の構造が25質量%であった。
4Si-GMA中の相対含有比は、下記(D3)の構造が82質量%で(D4)の構造が18質量%であった。
4Si-6PEG:合成例2で得られたシリコーンモノマー
NVP:N-ビニル-2-ピロリドン[CAS:88-12-0]
VMA:N-ビニル-N-メチルアセトアミド[CAS:3195-78-6]
TAIC:トリアリルイソシアヌレート[CAS:1025-15-6]
BDVE:1,4-ブタンジオールジビニルエーテル[CAS:3891-33-6]
TEGDVE:トリエチレングリコールジビニルエーテル[CAS:765-12-8]
EDMA:エチレングリコールジメタクリレート[CAS:97-90-5]
4G:テトラエチレングリコールジメタクリレート[CAS:109-17-1]
V-40:1,1’-アゾビス(シクロヘキサン-1-カルボニトリル)和光純薬工業株式会社、CAS:2094-98-6、10時間半減期温度:88℃
パーブチルO:t-ブチルパーオキシ-2-エチルヘキサノエート[日油株式会社、
CAS:3006-82-4、10時間半減期温度:72.1℃]
パーヘキサHC:1,1-ジ(t-ヘキシルパーオキシ)シクロヘキサン[日油株式会社、CAS:27215-08-3、22743-71-1、10時間半減期温度:87.1℃]
パーヘキシルI: t-ヘキシルパーオキシイソプロピルカーボネート[日油株式会社、
CAS:132929-84-1、10時間半減期温度:95.0℃]
マクロマーA:合成例3で得られたシロキサンマクロモノマー
マクロマーB:合成例4で得られたシロキサンマクロモノマー
FM-0711:モノメタクリロイル末端ポリジメチルシロキサン[JNC株式会社、製品名:サイラプレーンFM-0711]
TRIS:トリス(トリメチルシロキシ)-γ-メタクリロキシプロピルシラン[CAS:17096-07-0]
HEMA:2-ヒドロキシエチルメタクリレート[CAS:868-77-9]
DMAA:N,N-ジメチルアクリルアミド[CAS:2680-03-7]
2-MEA:2-メトキシエチルアクリレート[CAS:3121-61-7]
光重合開始剤
V-65:2,2’-アゾビス(2,4-ジメチルバレロニトリル)[和光純薬工業株式会社、CAS:4419-11-8、10時間半減期温度:51℃]
V-60:2,2’-アゾビスイソブチロニトリル[和光純薬工業株式会社、CAS:78-67-1、10時間半減期温度:65℃]
V-30:1-[(1-シアノ-1-メチルエチル)アゾ]ホルムアミド[和光純薬工業株式会社、CAS:10288-28-5、10時間半減期温度:104℃]
Darocur1173:2-ヒドロキシ-2-メチル-1-フェニルプロパン-1-オン[Sigma-Aldrich、CAS:7473-98-5]
PEG部分の繰り返し数が4のみであるシリコーンモノマーの合成
市販のテトラエチレングリコールを購入し、カラム精製によりPEG部分の繰り返し数を4のみとした(化合物1)。次に、テトラエチレングリコールの片末端のみをトリチルクロリドを用いて保護し(化合物2)、もう一方の片末端はアリルクロライドを用いてアリル化した(化合物3)。化合物3(15.0g:31.47mmol)にトリス(トリメチルシロキシ)シラン(9.34g:31.47mmol)、Platinum-divinyltetramethyldisiloxane complex in xylene(300μL)を加え、無溶媒で35℃で3日間加熱した。TLCで原料消失を確認後、カラム精製して化合物4(15.8g)を得た。
観測周波数:600MHz
測定溶媒:CDCl3
測定温度:300K
化学シフト基準:測定溶媒[7.25ppm]
レーザ光源:N2レーザー(波長:337nm)
測定モード:リフレクターモード、ポジティブイオンモード
測定質量範囲(m/z):20~1500
積算回数:1000回
イオン化試薬:トリフルオロ酢酸ナトリウム(THF溶液)
PEG部分の繰り返し数が6のみであるシリコーンモノマーの合成
市販のヘキサエチレングリコールを購入し、カラム精製によりPEG部分の繰り返し数を6のみとした(化合物6)。次に、ヘキサエチレングリコールの片末端のみをトリチルクロリドを用いて保護し(化合物7)、もう一方の片末端はアリルクロライドを用いてアリル化した(化合物8)。化合物8(17.8g:31.47mmol)にトリス(トリメチルシロキシ)シラン(9.34g:31.47mmol)、Platinum-divinyltetramethyldisiloxane complex in xylene(300μL)を加え、無溶媒で35℃で3日間加熱した。TLCで原料消失を確認後、カラム精製して化合物9(17.6g)を得た。次に、化合物9(5.56g:6.47mmol)にクロロホルム25mL、トリエチルシラン(827mg:7.11mmol)を加え、水冷下でBoron Trifluoride Diethyl Ether Complex(917.7mg:6.47mmol)を滴下後、30分撹拌した。TLC、LC-MSで目的物を確認後、反応液をクロロホルムで希釈、飽和食塩水で洗浄して、無水硫酸ナトリウムで乾燥後、濃縮して目的物の未精製物を得た。カラム精製、真空ポンプで終夜乾燥後、化合物10(2.40g)を得た。
マクロマーAの合成
容量100mLの三口フラスコに、両末端カルビノール変性ポリジメチルシロキサン(信越化学工業株式会社、製品名:KF-6001、重合度:20、水酸基当量:920g/モル)35g、イソホロンジイソシアネート8.29g(37.3mmol)、ジブチルスズジラウレート0.03gを入れ、窒素気流下にて、25℃で48時間撹拌した。次に、2-ヒドロキシエチルアクリレート4.97g(42.9mmol)と塩化メチレン20mLを入れ、引き続き窒素気流下にて、25℃で96時間撹拌した。反応終了後、蒸留水200mLで洗浄後、無水硫酸ナトリウムで乾燥後、溶媒を留去して目的物(40g)を得た。
得られた化合物は下記構造であることが確認され、また、ゲルパーミエーションクロマトグラフィーにより分子量測定を行った結果、数平均分子量は2400(ポリスチレン換算)であった。
カラム:Shodex KF-402.5HQ 2本
溶離液:THF
流 量:0.3mL/min
検出器:RI
カラム温度:40℃
マクロマーBの合成
容量100mLの三口フラスコに、両末端カルビノール変性ポリジメチルシロキサン(信越化学工業株式会社、製品名:KF-6001、重合度:20、水酸基当量:920g/モル)35g、イソホロンジイソシアネート8.29g(37.3mmol)、ジブチルスズジラウレート0.03gを入れ、窒素気流下にて、25℃で48時間撹拌した。次に、ポリエチレングリコールモノアクリレート(日油株式会社、製品名:ブレンマー AE-200、水酸基当量:317g/モル)13.6gと塩化メチレン20mLを入れ、引き続き窒素気流下にて、25℃で120時間撹拌した。反応終了後、蒸留水200mLで洗浄後、無水硫酸ナトリウムで乾燥後、溶媒を留去して目的物(45g)を得た。
得られた化合物は下記構造であることが確認され、また、ゲルパーミエーションクロマトグラフィーにより分子量測定を行った結果、数平均分子量は2550(ポリスチレン換算)であった。
容量20mLの褐色のガラス瓶に合成例3で得られたマクロマーAを1.5g(15質量%)、3Si-GMAを3g(30質量%)、HEMAを0.5g(5質量%)、NVPを5g(50質量%)、4Gを0.03g(マクロマーA、3Si-GMA、HEMAおよびNVPの合計量に対して0.3質量%)、TEGDVEを0.03g(マクロマーA、3Si-GMA、HEMAおよびNVPの合計量に対して0.3質量%)、パーブチルOを0.06g(マクロマーA、3Si-GMA、HEMAおよびNVPの合計量に対して0.6質量%)入れ、室温で約16時間撹拌した。このモノマー混合液をポリプロピレン製のコンタクトレンズ作製用の両面キャストモールド型(キャビティー表面の接触角は105°)に注入し、上型と下型を組み付けた後、加圧重合炉に入れた。重合炉内を20分間窒素で置換した後、0.2kgf/cm2の条件下で、下記に示す重合スケジュールにより重合した。
室温から50℃まで10分で昇温した後、そのまま50℃で8時間保持した。
[キュア条件]
ゲル化条件終了後、80℃まで5分で昇温し、そのまま80℃で2時間保持し、80℃から100℃まで10分で昇温した後、そのまま100℃で40分間保持し、さらに100℃から120℃まで10分で昇温した後、そのまま120℃で1時間保持することで重合を完結させた。
重合前のモノマー混合液の一部を透明なガラス瓶に入れ,目視で以下の評価基準に従い評価した。
評価基準
G(Good):モノマー混合液は溶解し均質である
B(Bad):モノマー混合液は二相に分離し溶解しない
得られたソフトコンタクトレンズを、目視で以下の評価基準に従い外観を評価した。
評価基準
G(Good):レンズは透明で、形状は円形を呈している
B(Bad):レンズは白濁しているか、あるいは透明であっても歪な形状を呈し、コンタクトレンズとしてふさわしくない
23℃で平衡膨潤に達したソフトコンタクトレンズの含水状態の重量(Ww)、および真空乾燥機で70℃、4時間乾燥させた乾燥状態の重量(Wd)を測定し、次式により含水率を算出した。
含水率(%)=(Ww-Wd)/Ww×100
厚さの異なるレンズを用いて、ISO 18369-4に記載のポーラログラフィー法による測定方法に従い酸素透過係数を測定した。測定にはRehder Development Company社のO2 Permometer Model 201Tを用いた。レンズの厚さをx軸に、測定により求められたt/Dk値をy軸にプロットし、回帰線の傾きの逆数を酸素透過係数とした。
ソフトコンタクトレンズ表面の水濡れ性を接触角測定により評価した。ソフトコンタクトレンズ表面の水分を拭き取った後、保持台にレンズを貼り付け、純水を用いた液滴法により接触角を測定した。測定には協和界面科学(株)社製の接触角計を用い、液滴の大きさはシリンジで約1.5mmとした。値が小さい方が水濡れ性に優れることを表す。
含水させたソフトコンタクトレンズを再乾燥し、コンタクトレンズ表面(十数nm深さ)に存在する元素の種類とその量をXPSにより分析した。なお測定箇所はソフトコンタクトレンズのフロントカーブ面の中心付近とし、表面の組成比はatomic%で示した。
照射X線:Al-Kα モノクロ φ100μm
光電子取出角:45度
帯電中和:10V Arイオン+20μA 電子線 同時照射
ソフトコンタクトレンズのモノマー組成のうち、重合開始剤をV-40に変更し、ゲル化条件を下記へと変更した以外は、実施例1と同様にレンズを作製した。得られたコンタクトレンズの接触角は40°であり、親水性表面を有するものであった(表1)。
室温から55℃まで10分で昇温した後、そのまま55℃で8時間保持し、さらに55℃から80℃まで5分で昇温した後、そのまま80℃で2時間保持した。
[キュア条件]
ゲル化条件終了後、100℃まで10分で昇温した後、そのまま100℃で40分間保持し、さらに100℃から120℃まで10分で昇温した後、そのまま120℃で1時間保持することで重合を完結させた。
ソフトコンタクトレンズのモノマー組成のうち、重合開始剤をパーヘキサHCに変更しゲル化条件を下記へと変更した以外は、実施例1と同様にレンズを作製した。得られたコンタクトレンズの接触角は33°であり、親水性表面を有するものであった(表1)。
実施例2と同様。
[キュア条件]
実施例2と同様。
ソフトコンタクトレンズのモノマー組成のうち、重合開始剤をパーヘキシルIに変更し、ゲル化条件を下記へと変更した以外は、実施例1と同様にレンズを作製した。得られたコンタクトレンズの接触角は53°であり、親水性表面を有するものであった(表1)。
室温から70℃まで10分で昇温した後、そのまま70℃で8時間保持し、さらに70℃から80℃まで5分で昇温した後、そのまま80℃で2時間保持した。
[キュア条件]
実施例2と同様。
ソフトコンタクトレンズのモノマー組成のうち、重合開始剤をV-65に変更した以外は、実施例1と同様にレンズを作製した。得られたコンタクトレンズの表面にはN-ビニル-2-ピロリドンに由来すると思われる窒素元素の割合が少なく、反対にシリコーン成分に由来するケイ素元素が多く分布し、レンズ表面の接触角は102°と水濡れ性に劣るものであった(表1)。
ソフトコンタクトレンズのモノマー組成のうち、重合開始剤をV-60に変更した以外は、実施例1と同様にレンズを作製した。得られたコンタクトレンズの表面にはN-ビニル-2-ピロリドンに由来すると思われる窒素元素の割合が少なく、反対にシリコーン成分に由来するケイ素元素が多く分布し、レンズ表面の接触角は102°と水濡れ性に劣るものであった(表1)。
ソフトコンタクトレンズのモノマー組成のうち、重合開始剤をV-30に変更し、ゲル化条件を下記へと変更した以外は、実施例1と同様にレンズを作製した。得られたコンタクトレンズは脆く、モールド型から取り出すことができなかった(表1)。
室温から70℃まで10分で昇温した後、そのまま70℃で8時間保持し、引き続き70℃から80℃まで5分で昇温した後、そのまま80℃で2時間保持した。さらに80℃から100℃まで10分で昇温した後、そのまま100℃で40分間保持した。
[キュア条件]
ゲル化条件終了後、100℃から120℃まで10分で昇温した後、そのまま120℃で1時間保持することで重合を完結させた。
容量20mLの褐色のガラス瓶に合成例4で得られたマクロマーBを1.5g(15質量%)、3Si-GMAを2.5g(25質量%)、FM-0711を0.8g(8質量%)HEMAを0.5g(5質量%)、NVPを4.7g(47質量%)、4Gを0.05g(マクロマーB、3Si-GMA、FM-0711、HEMAおよびNVPの合計量に対して0.5質量%)、BDVEを0.03g(マクロマーB、3Si-GMA、FM-0711、HEMAおよびNVPの合計量に対して0.3質量%)、パーブチルOを0.06g(マクロマーB、3Si-GMA、FM-0711、HEMAおよびNVPの合計量に対して0.6質量%)入れ、室温で約16時間撹拌した。このモノマー混合液をポリプロピレン製のコンタクトレンズ作製用の両面キャストモールド型に注入し、上型と下型を組み付けた後、加圧重合炉に入れた。重合炉内を20分間窒素で置換した後、0.2kgf/cm2の条件下で、下記に示す重合スケジュールにより重合した。
室温から50℃まで10分で昇温した後、そのまま50℃で8時間保持した。
[キュア条件]
実施例1と同様。
ソフトコンタクトレンズのモノマー組成のうち、重合開始剤をV-40に変更し、ゲル化条件を下記へと変更した以外は、実施例5と同様にレンズを作製した。得られたコンタクトレンズの接触角は40°であり、親水性表面を有するものであった(表2)。
室温から60℃まで10分で昇温した後、そのまま60℃で8時間保持し、引き続き60℃から80℃まで5分で昇温した後、そのまま80℃で2時間保持した。
[キュア条件]
実施例2と同様。
ソフトコンタクトレンズのモノマー組成のうち、重合開始剤をパーヘキサHCに変更し、ゲル化条件を下記へと変更した以外は、実施例6と同様にレンズを作製した。得られたコンタクトレンズの接触角は32°であり、親水性表面を有するものであった(表2)。
室温から60℃まで10分で昇温した後、そのまま60℃で8時間保持し、引き続き60℃から80℃まで5分で昇温した後、そのまま80℃で2時間保持した。
[キュア条件]
実施例2と同様。
ソフトコンタクトレンズのモノマー組成のうち、重合開始剤をパーヘキシルIに変更し、ゲル化条件を下記へと変更した以外は、実施例5と同様にレンズを作製した。得られたコンタクトレンズの接触角は44°であり、親水性表面を有するものであった(表2)。
室温から65℃まで10分で昇温した後、そのまま65℃で8時間保持し、引き続き65℃から80℃まで5分で昇温した後、そのまま80℃で2時間保持した。
[キュア条件]
実施例2と同様。
ソフトコンタクトレンズのモノマー組成のうち、重合開始剤をV-65に変更した以外は、実施例5と同様にレンズを作製した。得られたコンタクトレンズは円形ではなく歪な形状を呈し、コンタクトレンズとしてふさわしいものではなかった(表2)。
ソフトコンタクトレンズのモノマー組成のうち、重合開始剤をV-60に変更した以外は、実施例5と同様にレンズを作製した。得られたコンタクトレンズは円形ではなく歪な形状を呈し、コンタクトレンズとしてふさわしいものではなかった(表2)。
ソフトコンタクトレンズのモノマー組成のうち、重合開始剤をV-30に変更し、ゲル化条件を下記へと変更した以外は、実施例5と同様にレンズを作製した。得られたコンタクトレンズは脆く、モールド型から取り出すことができなかった(表2)。
室温から65℃まで10分で昇温した後、そのまま65℃で8時間保持し、引き続き65℃から80℃まで5分で昇温した後、そのまま80℃で2時間保持した。さらに80℃から100℃まで10分で昇温した後、そのまま100℃で40分間保持した。
[キュア条件]
ゲル化条件終了後、100℃から120℃まで10分で昇温した後、そのまま120℃で1時間保持することで重合を完結させた。
表3に示す組成でモノマー混合液を調製し、実施例1と同様にレンズを作製した。なおゲル化条件およびキュア条件は下記の通りとした。
室温から60℃まで10分で昇温した後、そのまま60℃で8時間保持し、引き続き60℃から80℃まで5分で昇温した後、そのまま80℃で2時間保持した。
[キュア条件]
実施例2と同様。
表4に示す組成でモノマー混合液を調製した以外は、実施例1と同様にレンズを作製した。なお、ゲル化条件及びキュア条件は、全て下記の通りとした。
室温から55℃まで10分で昇温した後、そのまま55℃で8時間保持し、引き続き55℃から80℃まで5分で昇温した後、そのまま80℃で2時間保持した。
[キュア条件]
実施例2と同様。
表4に示す組成でモノマー混合液を調製した以外は、実施例13と同様にレンズを作製した。得られたレンズは、レンズの構成成分としてN,N-ジメチルアクリルアミドを含むために、表面水濡れ性に劣るものであった。
表4に示す組成でモノマー混合液を調製し、モノマー混合液をポリプロピレン製のコンタクトレンズ作製用の両面キャストモールド型に注入し、上型と下型を組み付けた。このモールド型に、280~390nm領域の照射強度が11mW/cm2の光を20分間照射することで重合を完結させた。得られたレンズは、表面水濡れ性に劣るものであった。
実施例20と同一組成のモノマー混合液を調製し、このモノマー混合液をポリプロピレン製のコンタクトレンズ作製用の両面キャストモールド型に注入し、上型と下型を組み付けた後、加圧重合炉に入れた。重合炉内を30分間窒素で置換した後、0.2kgf/cm2の条件下で、下記に示す重合スケジュールにより重合した。
室温から55℃まで20分で昇温した後、そのまま55℃で40分間保持し、引き続き55℃から80℃まで5分で昇温した後、そのまま80℃で40分間保持した。
[キュア条件]
ゲル化条件終了後、80℃から100℃まで10分で昇温した後、そのまま100℃で40分間保持することで重合を完結させた。
実施例20と同一組成のモノマー混合液を調製し、ゲル化条件を下記へと変更した以外は比較例11と同様にレンズを作製した。得られたコンタクトレンズは脆く、モールド型から取り出すことができなかった。
室温から80℃まで25分で昇温した後、そのまま80℃で90分間保持することで重合を完結させた。
Claims (31)
- 疎水性キャビティ表面を有するモールド型のキャビティにおいて、
(a)少なくとも1種の(メタ)アクリロイル基を有するシリコーンモノマー、(b)少なくとも1種のビニル基を有する親水性モノマー、(c)少なくとも1種の架橋性モノマー及び(d)少なくとも1種の重合開始剤を含有するモノマー溶液を重合して、
親水性表面を有する、シリコーンモノマー単位、親水性モノマー単位及び架橋性モノマー単位を含有するシリコーン含有共重合体成形品を作製する方法であって、
前記重合開始剤は、10時間半減期温度(以下、T10と略記する)が70℃以上、100℃以下であり、
前記重合を、前記モノマー溶液に含有される重合開始剤のT10からT10より35℃低い温度の範囲内で1時間又はそれ以上維持するP1工程、及び前記モノマー溶液に含有される重合開始剤のT10より高い温度で1時間又はそれ以上維持するP2工程で行う、前記方法。 - 前記P1工程における維持温度が、前記T10より10℃低い温度からT10より35℃低い温度の範囲である請求項1に記載の方法。
- P2工程における維持温度が、前記T10より5℃高い温度からT10より50℃高い温度の範囲である請求項1又は2に記載の方法。
- 前記重合開始剤が、アゾ重合開始剤又は有機過酸化物重合開始剤である請求項1~3のいずれか1項に記載の方法。
- 前記シリコーン含有共重合体成形品の前記シリコーンモノマー(a)単位の含有量が20~56質量%の範囲であり、前記親水性モノマー(b)単位の含有量が40~60質量%の範囲であり、前記架橋性モノマー(c)単位の含有量が0.02~4質量%の範囲である請求項1~4のいずれか1項に記載の方法。
- 前記シリコーンモノマー(a)が下記(a1)及び(a2)から成る群から選ばれる少なくとも1種のモノマーである請求項1~5のいずれか1項に記載の方法。
(a1)少なくとも1つの水酸基及び1個~4個のケイ素原子を1分子中に含有するシリコーンモノマーの1種又は2種以上、
(a2)少なくとも1つのポリエチレングリコール基及び1個~4個のケイ素原子を1分子中に含有するシリコーンモノマーの1種又は2種以上。 - 前記親水性モノマー(b)が、N-ビニル-2-ピロリドン及びN-ビニル-N-メチルアセトアミドから選択される1種又は2種である、請求項1~7のいずれか1項に記載の方法。
- 前記架橋性モノマー(c)が、(c1)、(c2)及び(c3)から成る群から選ばれる少なくとも1種のモノマーである請求項1~8のいずれか1項に記載の方法。
(c1)1分子中に2つ以上のビニル基を含有するモノマーの1種又は2種以上、
(c2)1分子中に2つ以上のアリル基を含有するモノマーの1種又は2種以上、
(c3)1分子中に2つ以上の(メタ)アクリレート基を有するモノマーの1種又は2種以上。 - 前記モノマー(c1)が、1,4-ブタンジオールジビニルエーテル、ジエチレングリコールジビニルエーテル、及びトリエチレングリコールジビニルエーテルから選択される1種又は2種以上であり、
前記モノマー(c2)が、トリアリルイソシアヌレート、トリメチロールプロパンジアリルエーテル、及びペンタエリスリトールトリアリルエーテルから選択される1種又は2種以上であり、
前記モノマー(c3)が、エチレングリコールジ(メタ)アクリレート、トリエチレングリコールジ(メタ)アクリレート、テトラエチレングリコールジ(メタ)アクリレート、トリメチロールプロパントリ(メタ)アクリレート、及びエトキシ化トリメチロールプロパントリ(メタ)アクリレートから選ばれる1種又は2種以上のモノマーである請求項9に記載の方法。 - 前記モノマー溶液は、シロキサンマクロモノマー、分子構造中に水酸基またはポリエチレングリコール基を含まないシリコーンモノマー、及び分子構造中にケイ素原子を含まないモノマーから成る群から選ばれる少なくとも1種の補助モノマーをさらに含有する請求項1~10のいずれか1項に記載の方法。
- 前記シリコーン含有共重合体成形品の親水性表面は、重合後の成形品表面に表面の水濡れ性を良化させるための後処理を施さない状態で、純水に対する接触角が60°以下である(但し、前記接触角はシリコーン含有共重合体成形品を含水させたシリコーンハイドロゲル成形品の接触角である)請求項1~11のいずれか1項に記載の方法。
- 疎水性キャビティ表面を有するモールド型がポリアルキレン製コンタクトレンズ成形用両面キャストモールドであり、前記シリコーン含有共重合体成形品が、シリコーンハイドロゲルソフトコンタクトレンズ用前駆体である請求項1~12のいずれか1項に記載の方法。
- 請求項1~13のいずれか1項に記載の方法で調製されたシリコーン含有共重合体成形品。
- 下記(a1)及び(a2)から成る群から選ばれる少なくとも1種のモノマー単位、下記(b)のモノマー単位、及び(c1)~(c3)から成る群から選ばれる少なくとも1種のモノマー単位からなり(但し、(g)分子構造中にケイ素原子を含まないモノマー単位をさらに含むことができ、(g)分子構造中にケイ素原子を含まないモノマーは、2-ヒドロキシエチル(メタ)アクリレート、メタクリル酸、メチル(メタ)アクリレート、エチル(メタ)アクリレート、n-ブチル(メタ)アクリレート、2-メトキシエチル(メタ)アクリレート、2-メタクリロイルオキシエチルホスホリルコリンなどから選らばれる1種以上のモノマーである)、純水に対する接触角が60°以下である親水性表面を有する(但し、接触角はシリコーン含有共重合体成形品を含水させたシリコーンハイドロゲル成形品の接触角である)シリコーン含有共重合体成形品であって、前記シリコーンモノマー(a1)~(a2)単位の含有量が20~56質量%の範囲であり、前記モノマー(b)単位の含有量が40~60質量%の範囲であり、前記モノマー(c1)~(c3)単位の含有量が0.02~4質量%の範囲であり、かつ前記(g)分子構造中にケイ素原子を含まないモノマー単位の含有量が10質量%未満の範囲である、前記シリコーン含有共重合体成形品。
(a1)少なくとも1つの水酸基及び1個~4個のケイ素原子を1分子中に含有し、分子量が900未満であるシリコーンモノマーに由来する単位の1種又は2種以上、
(a2)少なくとも1つのポリエチレングリコール基及び1個~4個のケイ素原子を1分子中に含有し、分子量が900未満であるシリコーンモノマー単位の1種又は2種以上、
(b)ビニル基を有する親水性モノマーに由来する単位の1種又は2種以上、
(c1)1分子中に2つ以上のビニル基を含有するモノマー単位の1種又は2種以上、
(c2)1分子中に2つ以上のアリル基を含有するモノマー単位の1種又は2種以上、
(c3)1分子中に2つ以上の(メタ)アクリレート基を有するモノマーの1種又は2種以上。 - 下記(a1)及び(a2)から成る群から選ばれる少なくとも1種のモノマー単位、下記(b)のモノマー単位、(c1)~(c3)から成る群から選ばれる少なくとも1種のモノマー単位、及び(e)のシロキサンマクロモノマー単位を含有し、純水に対する接触角が60°以下である親水性表面を有し、かつ含水率が35%以上、60%未満である(但し、接触角及び含水率は、それぞれシリコーン含有共重合体成形品を含水させたシリコーンハイドロゲル成形品の接触角及び含水率である)シリコーン含有共重合体成形品。
(a1)少なくとも1つの水酸基及び1個~4個のケイ素原子を1分子中に含有し、分子量が900未満であるシリコーンモノマーに由来する単位の1種又は2種以上、
(a2)少なくとも1つのポリエチレングリコール基及び1個~4個のケイ素原子を1分子中に含有し、分子量が900未満であるシリコーンモノマー単位の1種又は2種以上、
(b)ビニル基を有する親水性モノマーに由来する単位の1種又は2種以上、
(c1)1分子中に2つ以上のビニル基を含有するモノマー単位の1種又は2種以上、
(c2)1分子中に2つ以上のアリル基を含有するモノマー単位の1種又は2種以上、
(c3)1分子中に2つ以上の(メタ)アクリレート基を有するモノマーの1種又は2種以上
(e)一般式(C1)および(C2)のマクロモノマーの1種又は2種以上
- rは0~8であり、pは8~50であり、qは9~13であり、tは0~2である請求項16に記載のシリコーン含有共重合体成形品。
- 前記親水性モノマー(b)が、N-ビニル-2-ピロリドン及びN-ビニル-N-メチルアセトアミドから選択される1種又は2種である、請求項15~19のいずれか1項に記載のシリコーン含有共重合体成形品。
- 前記モノマー(c1)が、1,4-ブタンジオールジビニルエーテル、ジエチレングリコールジビニルエーテル、及びトリエチレングリコールジビニルエーテルから選択される1種又は2種以上であり、
前記モノマー(c2)が、トリアリルイソシアヌレート、トリメチロールプロパンジアリルエーテル、及びペンタエリスリトールトリアリルエーテルから選択される1種又は2種以上であり、かつ
前記モノマー(c3)が、エチレングリコールジ(メタ)アクリレート、トリエチレングリコールジ(メタ)アクリレート、テトラエチレングリコールジ(メタ)アクリレート、トリメチロールプロパントリ(メタ)アクリレート、及びエトキシ化トリメチロールプロパントリ(メタ)アクリレートから選ばれる1種又は2種以上のモノマーである請求項15~20のいずれか1項に記載のシリコーン含有共重合体成形品。 - 前記シリコーンモノマー(a1)及び(a2)単位の含有量が20~56質量%の範囲であり、前記モノマー(b)単位の含有量が40~60質量%の範囲であり、かつ前記モノマー(c1)、(c2)及び(c3)単位の含有量が0.02~4質量%の範囲である請求項16~21のいずれか1項に記載のシリコーン含有共重合体成形品。
- 前記(e)のシロキサンマクロモノマー単位の含有量が25質量%以下である請求項16~22のいずれか1項に記載のシリコーン含有共重合体成形品。
- 前記シリコーン含有共重合体成形品は、分子構造中に水酸基またはポリエチレングリコール基を含まないシリコーンモノマー単位、及び分子構造中にケイ素原子を含まないモノマー単位から成る群から選ばれる少なくとも1種の追加モノマー単位をさらに含有する請求項16~23のいずれか1項に記載のシリコーン含有共重合体成形品。
- 純水に対する接触角が60°以下である親水性表面は、重合後のレンズ形状材料に表面の水濡れ性を良化させるための後処理を施すことなく得られたものである、(但し、前記接触角はシリコーン含有共重合体成形品を含水させたシリコーンハイドロゲル成形品の接触角である)請求項15~24のいずれか1項に記載のシリコーン含有共重合体物品。
- 請求項14~25のいずれか1項に記載のシリコーン含有共重合体成形品であり、かつコンタクトレンズ形状を有する、シリコーンハイドロゲルソフトコンタクトレンズ用前駆体。
- 請求項26に記載のシリコーンハイドロゲルソフトコンタクトレンズ前駆体を生理食塩水またはソフトコンタクトレンズ用保存液にて含水状態にしたシリコーンハイドロゲルソフトコンタクトレンズ。
- 前記含水状態にしたシリコーンハイドロゲルソフトコンタクトレンズは含水率が35%以上、60%未満である請求項27に記載のソフトコンタクトレンズ。
- 前記含水状態にしたシリコーンハイドロゲルソフトコンタクトレンズは、交換頻度が最長1ヶ月までのソフトコンタクトレンズである請求項27又は28に記載のソフトコンタクトレンズ。
- 前記含水状態にしたシリコーンハイドロゲルソフトコンタクトレンズは、交換頻度が1日または2週間のタイプである請求項29に記載のソフトコンタクトレンズ。
- 請求項27~30のいずれか1項に記載のソフトコンタクトレンズ及び生理食塩水またはソフトコンタクトレンズ用保存液を密閉容器に格納した、パッケージ入りソフトコンタクトレンズ製品。
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CN102964532A (zh) | 2012-11-29 | 2013-03-13 | 海昌隐形眼镜有限公司 | 一种有机硅水凝胶隐形眼镜材料及其制备方法 |
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TWI642728B (zh) * | 2016-05-12 | 2018-12-01 | 詹前慶 | 一種矽水膠組合物及其製備之鏡片 |
US10172358B2 (en) | 2016-08-30 | 2019-01-08 | Dow Agrosciences Llc | Thiopicolinamide compounds with fungicidal activity |
US11278489B2 (en) * | 2016-09-23 | 2022-03-22 | Menicon Co., Ltd. | Cosmetic composition for nails, method of using same, and cosmetic resin for nails |
US10246417B2 (en) | 2017-01-05 | 2019-04-02 | Dow Agrosciences Llc | Picolinamides as fungicides |
JP2019053125A (ja) * | 2017-09-13 | 2019-04-04 | 日油株式会社 | コンタクトレンズ用モノマー組成物、コンタクトレンズ用重合体及びその製造方法、並びにコンタクトレンズ及びその製造方法 |
WO2019218063A1 (en) * | 2018-05-16 | 2019-11-21 | Gl Chemtec Vision Inc. | Hydrogel polymers |
WO2020054711A1 (ja) | 2018-09-14 | 2020-03-19 | 日油株式会社 | コンタクトレンズ用モノマー組成物、その重合体、ならびにコンタクトレンズおよびその製造方法 |
KR20210057041A (ko) | 2018-09-14 | 2021-05-20 | 니치유 가부시키가이샤 | 콘택트 렌즈용 모노머 조성물, 그 중합체, 그리고 콘택트 렌즈 및 그 제조 방법 |
WO2022224790A1 (ja) | 2021-04-21 | 2022-10-27 | 日油株式会社 | コンタクトレンズ用モノマー組成物、その重合体、ならびにコンタクトレンズおよびその製造方法 |
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AU2014250655A1 (en) | 2015-01-22 |
US9529119B2 (en) | 2016-12-27 |
HK1203447A1 (zh) | 2015-10-30 |
TW201502172A (zh) | 2015-01-16 |
EP2926967A1 (en) | 2015-10-07 |
CA2876538A1 (en) | 2015-01-08 |
KR101921846B1 (ko) | 2018-11-23 |
AU2014250655B2 (en) | 2017-11-02 |
CN104602886A (zh) | 2015-05-06 |
EP2845708A4 (en) | 2015-08-19 |
KR20170039314A (ko) | 2017-04-10 |
PH12014502313B1 (en) | 2015-02-02 |
TWI620771B (zh) | 2018-04-11 |
SG10201610094TA (en) | 2017-01-27 |
JP5452756B1 (ja) | 2014-03-26 |
KR20150067085A (ko) | 2015-06-17 |
ES2592254T3 (es) | 2016-11-29 |
PL2845708T3 (pl) | 2016-12-30 |
EP2845708A1 (en) | 2015-03-11 |
PH12014502313A1 (en) | 2015-02-02 |
MX2014014466A (es) | 2015-03-04 |
MY170066A (en) | 2019-07-03 |
HUE031087T2 (en) | 2017-06-28 |
JP2015011314A (ja) | 2015-01-19 |
MX2019008431A (es) | 2019-09-18 |
EP2845708B1 (en) | 2016-07-06 |
CA2876538C (en) | 2019-04-09 |
US20160282516A1 (en) | 2016-09-29 |
MX369026B (es) | 2019-10-25 |
KR101735900B1 (ko) | 2017-05-15 |
CN104602886B (zh) | 2017-03-15 |
HK1211264A1 (en) | 2016-05-20 |
SG11201406616UA (en) | 2015-02-27 |
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