Process of Forming a Hydroxy-Substitute Polymeric Shaped Article

A mixture of 50 g vinyl trifluoroacetate, 0.75 g vinyl acetate and 0.25 g of decanoyl peroxide was placed in an ampoule. The ampoule was sealed and maintained at 47.degree. C. for about 16 hours, then at 57.degree. C. for two hours. The product, poly(vinyl trifluoroacetate-co-vinylacetate) copolymer had a softening temperature of 180.degree. C., was removed from the ampoule, pressed at 191.degree. C. for about 1 minute into sheets and solvolyzed by treating with 10 percent ammonium hydroxide in methanol. The product was poly(vinyl alcohol-co-vinyl acetate) copolymer. The nuclear magnetic resonance spectrum of the copolymer was consistent with the assigned structure.

A mixture of 50 g vinyl trifluoroacetate, 0.75 g vinyl acetate, and 0.05 g 2-hydroxy-2-methyl-1-phenyl-1-propanone was placed in an ampoule. The ampoule was sealed and then rotated under an ultraviolet sunlamp for about three hours. Air was blown over the ampoule during the irradiation to cool it. The product, poly(vinyl trifluoroacetate-co-vinyl acetate) copolymer (softening temperature 180.degree. C.), was removed from the ampoule and pressed into sheets at 191.degree. C. (375.degree. F.) for two minutes. The sheets were solvolyzed in 10 percent ammonium hydroxide in methanol for thirty minutes to provide poly(vinyl alcohol-co-vinyl acetate) copolymer.

A mixture of 5 g of vinyl trifluoroacetate, 0.030 g of maleic anhydride, and 0.025 g of azobisisobutyronitrile was placed in an ampoule, the contents of the ampoule were frozen with liquid nitrogen, the ampoule was degassed under a vacuum and then sealed. The ampoule was heated in a bath at 47.degree. C. for about 16 hours. The contents of the ampoule were found to be white solid poly(vinyl trifluoroacetate-maleic anhydride) copolymer having a softening temperature of 180.degree. C.

The product of Example 3 was thermoformed by pressing between two polyester sheets at 180.degree. C. (356.degree. F.) for 0.75 minutes. A polymeric article with good strength was obtained. After cooling, the polymer film was placed in a flask and 20 ml of 10 percent concentrated ammonium hydroxide in methanol was added. After standing for 15 minutes, the polymer was separated by decanting the liquids, then dried in air to provide a poly(vinyl alcohol-maleic anhydride) copolymer in which the anhydride functional group had been converted to a carboxylate and an amide group. The copolymer was found to form a hydrogel when water was added, in that water absorption to a clear, strong elastic film occurred without dissolving the polymer sample.

Using the method of Example 1, vinyl trifluoroacetate was copolymerized with various monomers at a weight ratio of 99 to 1 to provide the copolymers (all having softening temperatures of 180.degree. C.) shown in the examples of TABLE I:

Using the method of Example 4, the copolymers of the above examples were thermoformed, then solvolyzed and hydrated to provide the copolymers of TABLE II.

To a solution of 18.0 g of trichloroacetyl chloride in 100 ml of chloroform was added 14.2 g glycidyl methacrylate. The solution was warmed to 50.degree. C., then stirred at 20.degree. C. for 16 hours. The solution was then heated at reflux for 22 hours, the chloroform was removed by evaporation under vacuum to provide a mixture of 68 weight percent of 1-chloro-3-(trichloroacetoxy)propyl-2-methacrylate and 32 weight percent of 2-chloro-3-(trichloroacetoxy)propyl-1-methacrylate according to infrared and nuclear magnetic resonance spectral analyses.

Into a cold solution (ice bath) of 7.1 g (50 mmole) of glycidyl methacrylate in 100 ml of dichloromethane was bubbled 6.0 g (45 mmole) of trifluoroacetyl chloride. The solution was allowed to stand at 20.degree. C. for 16 hours then evaporated to remove low boiling components. The residue was distilled in vacuo after the addition of 0.5 g methylene blue. Fractions boiling between 53.degree. and 60.degree. C. at 0.4 mm of Hg were analyzed by gas-liquid phase chromatography to show a single major component. Infrared and nuclear magnetic resonance spectral analyses confirmed the product to be 1-chloro-3-(trifluoroacetoxy)propyl-2-methacrylate.

To a cold solution (0.degree. C.) of 25 g (120 mmole) of trifluoroacetic anhydride and 2 drops of trifluoroacetic acid in 100 ml of dichloromethane was added dropwise 14.2 g (100 mmole) of glycidyl methacrylate. The mixture was then allowed to warm to 20.degree. C. and stirred for 20 hours. The solvent was removed by evaporation and the residue was distilled in vacuo to provide 1,3-bis(trifluoroacetoxy)propyl-2-methacrylate, b.p. 85.degree. C./0.2 mm of Hg. The structural assignment was confirmed by infrared and nuclear magnetic resonance spectral analyses.

A copolymer of 99.5 weight percent vinyl trifluoroacetate and 0.5 weight percent maleic anhydride prepared according to the method of Example 2 was dissolved in acetone to give a 20 weight percent solution. The solution was cast onto a clear polyester film in sufficient thickness to give, after solvent evaporation, a clear film of approximately 0.4 mm (0.015 inches) thickness. This film having a softening temperature of 180.degree. C. was placed in a metal mold designed to form a single contact lens, and the mold (heated at 200.degree. C.) was closed under pressure (hydraulic ram pressure of approximately 1000 psi or 70 kg/cm.sup.2) for two minutes.

The mold was cooled and the molded lens was removed and placed in a container with 20 ml of 9/1 methanol/concentrated ammonium hydroxide for 15 minutes. The solvolyzed contact lens was then air dried and placed in distilled water. Hydration to a clear, flexible, very strong hydrogel lens (water sorption level 65 weight percent) occurred.

To a stirred solution of 6.0 g (19.4 mmole) of trichloroacetic anhydride in 25 ml of acetonitrile was added dropwise 1.4 g of glycidyl methacrylate. The reaction was stirred for 16 hours. The solvent was removed in vacuo and the product analyzed by nuclear magnetic resonance and infrared spectra. The analysis showed that the product obtained was 1,3-bis(trichloroacetoxy)propyl-2-methacrylate.

To a stirred ice-bath cooled sample of 63 g of trifluoroacetic anhydride was added slowly 26 g of hydroxyethyl methacrylate. After stirring about 16 hours at 20.degree. C. the solution was poured into a mixture of ice and diethyl ether. The ether layer was washed several times with ice water, then with cold saturated sodium bicarbonate solution until carbon dioxide was no longer evolved. The ether layer was then washed with cold sodium chloride solution and dried over magnesium sulfate. Evaporation of the ether provided 40.3 g of product. Distillation from methylene blue (2 g) provided 21.9 g of product, trifluoroacetoxyethyl methacrylate, b.p. 57.degree.-58.degree. C./3.0 mm of Hg. Chromatographic analysis showed 99 percent purity. Infrared and nuclear magnetic resonance spectral analyses confirmed the structural assignment.

To a mixture of 3.6 g of methyl methacrylate and 14.4 g of 1,3-bis(trifluoroacetoxy)propyl-2-methacrylate (prepared according to Example 13) was added 20 mg of diisopropyl percarbonate. Nitrogen was bubbled through the solution for 30 minutes. The solution was polymerized by heating at 60.degree. C. for 4 hours in a Teflon container 1.26 mm in thickness. The resulting polymer had a softening temperature between 107.degree. and 149.degree. C. was thermally molded by holding at 149.degree. C. (300.degree. F.) for 10 minutes in a contact lens mold made of metal. The lens was placed in a stirred 1 M aqueous ammonium hydroxide solution for about 16 hours then rinsed with distilled water. The lens remained transparent and retained its shape.

A mixture of 12 g of 1,3-bis(trifluoroacetoxy)propyl-2-methacrylate (prepared according to Example 13), 1.5 g of methyl methacrylate, 1.5 g of ethoxyethyl methacrylate and 17 mg diisopropyl percarbonate was degassed by bubbling through nitrogen gas. A film cell consisting of two glass plates separated by a washer-like spacer of poly(tetrafluoroethylene) of about 12 mil (0.3 mm) thickness was filled with this solution and the mixture was polymerized at 60.degree. C. for 4.75 hours. The film was placed in 1 M ammonium hydroxide solution and stirred for 26.5 hours. The film was then rinsed three times with distilled water and mixed in 0.9 weight percent sodium chloride solution for 18 hours. The weight percent hydration of the film was determined to be 40.6.

To a mixture of 3.6 g of ethoxyethyl methacrylate and 14.4 g of 1,3-bis(trifluoroacetoxy)propyl-2-methacrylate (prepared according to Example 13) was added 20 mg of diisopropyl percarbonate. The solution was degassed with nitrogen and poured into a polymerization cell. Polymerization was carried out at 65.degree. C. for 14 hours. The resulting polymer had a softening temperature between 107.degree. and 177.degree. C. and was thermoformed at 177.degree. C. (350.degree. .F) for five minutes. The article was placed in stirred 1 M ammonium hydroxide for 24 hours, then rinsed in distilled water for 24 hours, to provide a hydrated article which retains 64 weight percent water.

To 10 g of 1,3-bis(trifluoroacetoxy)propyl-2-methacrylate (prepared as in Example 13) was added 30 mg of diisopropyl percarbonate. Nitrogen was bubbled through the solution. After 20 minutes the solution was injected into a film cavity with a 1.02 mm (40 mil) thick Teflon.RTM. spacer. This container was placed in a 78.degree. C. oven for 3.5 hours. The homopolymer film was then immersed in water on a steam bath for 22.5 hours. The water content was determined to be 82 weight percent.

To 17 g of trifluoroacetoxyethyl methacrylate prepared as in Example 16) was added 25 mg of diisopropyl percarbonate. The solution was degassed with nitrogen and then used to fill a glass plate cell. The film was cured at 65.degree. C. for four hours. The polymer film obtained from the cell had a softening temperature between 107.degree. and 300.degree. C. The film was pressed between two pieces of Teflon.RTM. at 300.degree. C. and was found to be thermoplastic.

A mixture of 8 g of 1,3-bis(trifluoroacetoxy)propyl-2-methacrylate, 8 g of vinyl trifluoroacetate and 40 mg (0.25%) of diisopropyl percarbonate was degassed. The mixture was injected between two glass plates and heated at 38.degree. C. for one day, then heated at 60.degree. to 65.degree. C. for two hours.

The film was soaked for 3.5 hours in 1 M ammonium hydroxide solution, then rinsed thoroughly three times with distilled water. The film absorbed 85 weight percent water, had gas phase oxygen permeability of 48 (cm.sup.2)(ml O.sub.2)/sec (ml)(mm).sup.2, and flow conductivity of 9.7.times.10.sup.-13 .+-.0.5 cm.sup.2 /sec. dynes and can be used as a corneal implant or intraocular lens.

A soft intraocular lens material was prepared using the 98.5% of polyvinyl trifluoroacetate and 1.5% of polyvinyl acetate copolymer of the invention prepared as described in Example 2 by ultraviolet light induced copolymerization. A pair of disk shaped prostheses were cut with a diamond saw from disks of the dry polymer of about 0.2 mm thickness. The outside diameter of each disk was 14 mm. The dry disks were then solvolyzed using methanolic ammonium hydroxide to provide a poly(vinyl alcohol) copolymer. The disks were hydrated with distilled water to a water content of 70% and inserted into the posterior chamber of the right eye of a New Zealand white rabbit using standard medical techniques. The eyes were examined regularly using a slit lamp. After ten months the rabbit eye was observed to be healthy, the lens was clear, no evidence of tissue adherence was observed and the implantation was judged successful.

A sheet of hydrogel copolymer material of the invention was prepared and used as a source of corneal implant prosthesis material. The polyvinyl trifluoroacetate copolymer was prepared according to the method of Example 2 by ultraviolet light induced copolymerization. A pair of disk-shaped prostheses were cut from disks of dry copolymer with a diamond saw to a thickness of about 0.2 mm and a diameter of 7 mm. The dry disk was then converted to a polyvinyl alcohol-polyvinyl acetate copolymer hydrogel by methanolic ammonium hydroxide solvolysis. Each disk was hydrated to a water content of 70%. The disks were inserted into a pocket located midstroma about 0.24 mm below the epithelial layer of the eye of a New Zealand white rabbit. The pocket was closed using 10-0 nylon stitching for the sutures. The eyes were treated to prevent infection using standard techniques. After fifteen days the rabbit was sacrificed and the eyes examined for effects due to the implant. A slight pannus ingrowth was observed and the cornea was slightly translucent where it had been in contact with the posterior side of the implant due to the manipulation of the tissue to form a pocket. The anterior surface of the cornea above the implant was clear with no indication of extrusion. The implant was well tolerated in terms of not causing toxic effects.

Using the method of Example 23 disks were obtained for implantation into the cornea of a primate. Disks were inserted into both eyes of the primate by cutting corneal pocket incisions and inserting the disks using standard medical procedures. The eyes were examined regularly using a slit lamp and were observed to heal in a satisfactory manner. After four months the animal was sacrificed and the eyes carefully examined. No infection, swelling or evidence of implant material extrusion was observed.

A mixture of 1 part vinyl trifluoroacetate monomer, 3 parts of Freon.TM. 113 (1,1,2-trichloro-2,2,1-trifluoroethane), and 0.0040 parts of 2-hydroxy-2-methyl-1-phenyl-1-propanone photoinitiator was placed in a glass vial and purged by bubbling carbon dioxide gas through the solution. The vial was sealed and irradiated for one hour using an ultraviolet lamp. This process was conducted at room temperature. The reaction mixture was filtered, the solid product was resuspended in 3 parts of Freon 113 and filtered again giving a white crystalline solid product, poly(vinyl trifluoroaetate), which was air-dried. Analysis by differential scanning calorimetry showed the crystalline melting transition for this polymer is complete at 180.degree. C. and this represents the softening temperature.

A mixture of 551 grams of vinyl trifluoroacetate monomer, 4000 grams of Freon 113, and 35 ml of a 10% solution of dicyclohexyl peroxydicarbonate in Freon 113 was placed in a reactor equipped with stirrer and thermometer. The mixture was purged with nitrogen gas, the reactor was sealed, and stirred at 50.degree. C. for 18 hours. The reactor contents, a white solid product suspended in Freon 113, were filtered, washed with Freon 113, and the solid product was dried in a vacuum oven to give a white solid crystalline powder product, the homopolymer of vinyl trifluoroacetate. Analysis by differential scanning calorimetry showed the crystalline melting transition for this polymer to be complete at 180.degree. C. and this represents the softening temperature.

Homopolymer of poly(vinyl trifluoroacetate) as prepared in Example 26 or 27 was dissolved in acetone to give a 20% solution of polymer. The solution was filtered and a film was prepared by evaporation of the acetone solvent. This film was treated for 2 hours in a solution of 10 parts concentrated ammonium hydroxide in 90 parts of methanol at room temperature, washed in fresh methanol and swollen in water to give a strong transparent poly(vinyl alcohol) homopolymer hydrogel of about 50 weight percent water. The hydrogel film had a refractive index of 1.42, a tensile strength of about 97 kg/cm.sup.2, and was very well wetted by water as shown by a water droplet contact angle of just 24.degree.. This film was found to be suitable for use as a corneal implant or intraocular lens.

A homopolymer of poly(vinyl trifluoroacetate) was prepared using the procedure of Example 3 but using no comonomer. Thermoforming and then solvolysis according to the method of Example 4 provided a film of poly(vinyl alcohol) having the following properties:

This film can be used to make an intraocular lens.

Various modifications and alterations of this invention will become apparent to those skilled in the art without departing from the scope and spirit of this invention, and it should be understood that this invention is not to be unduly limited to the illustrative embodiments set forth herein.