US 4,861,850 AGrant
Ophthalamic Device From Fluoro-Silicon Polymers
Issue Date:1989-08-29
•8 Claims
Abstract
Comfortable, oxygen permeable hard and semi-hard contact lenses are made from the copolymer of ethylenically unsaturated siloxanylalkoxy ester monomer, ethylenically unsaturated fluorocarbon ester monomer and ethylenically unsaturated sulfone monomer; the copolymer plastic can be modified by the incorporation of hardening, stability and wettability agents and methods for the manufacture thereof.
Metadata
Assignee
- Progressive Chemical Research, Ltd.
Inventor
- Nick N. Novicky
Application Information
Application Number:US 153811&
Filing Date:1988-02-08
Priority Date:1987-06-30
Art Unit:155
Classifications
IPC:
G02C 704C08F23008
Field of Search:
526350243;244;245;264;270;273;286160 R;160 H
Patent Drawings
This patent does not have any drawings.
Description
Background of the Invention
Oxygen permeable contact lenses in the prior art are essentially made from siloxane monomer and methyl methacrylate. These lenses are permeable to oxygen; hence, allowing oxygen from the air to pass through the lenses and reach the cornea which allows such lenses to be worn for longer periods of tome as compared to non-oxygen permeable contact lenses such as PMMA which were available previously.
Such contact lenses were disclosed in the prior art by Gaylord, U.S. Pat. Nos. 3,808,178 and 4,120,570. Later, Ellis disclosed in his patents, U.S. Pat. Nos. 4,152,508 and 4,330,383, the partial replacement of the methyl methacrylate monomer with dimethyl itaconate. The Novicky patents, U.S. Pat. Nos. 4,216,303, 4,242,483, 4,248,989, 4,303,772 and 4,365,074, disclosed contact lenses comprised of high molecular weight of polysiloxanylalkyl esters of acrylic and methacrylic acids. The Chang patent, U.S. Pat. No. 4,182,822, disclosed contact lenses comprised of a copolymer from polysiloxanylalkyl ester of acrylic and methacrylic acid essentially the same as disclosed in the Gaylord patents, supra., that were copolymerized with N-vinyl pyrrolidinone or N,N-dimethyl methacrylamide.
In Ichinoche, et al., Canadian Patent No. 1,184,341, it teaches the use of organosiloxanyl ester monomer of acrylic and methacrylic acid copolymerized with fluorocarbon ester monomers of acrylic and methacrylic acids and copolymerized to produce oxygen permeable contact lenses. The LeBoeuf patent, U.S. Pat. No. 4,246,389, discloses acrylic siloxane based polymers which also contain HEMA and polyvinyl 2-pyrrolidinone which are suitable for use in forming water-containing oxygen permeable contact lenses.
All siloxane ester monomers in the prior art employ essentially the same alkyl bridge between methacryloxy group and siloxanyl part of the structure; wherein, neither one used ethoxy group or 2,3-dioxypropyl groups. The organosilicone monomers of the present invention can be copolymerized with perfluoroalkyl ester monomers and with sulfone monomers.
Summary of the Invention
The present invention relates to a novel and new generation of contact lenses comprising of copolymers made from siloxanylalkoxy ester monomers of acrylic, methacrylic, itaconic acids or mixtures thereof and perfluoroalkyl ester monomers of acrylic, methacrylic, itaconic acid or mixtures thereof which are copolymerized with ethylenically unsaturated sulfone alkyl monomers and ethylenically unsaturated sulfone ester monomers of acrylic, methacrylic, itaconic acid or mixtures thereof, to produce highly oxygen permeable and improved materials for contact lenses.
The first representative siloxanylalkoxy ester monomer of acrylic or methacrylic acid of the present invention has the general structural formula: ##STR1## wherein X and Y are C.sub.1 to C.sub.6 alkyl, cyclic, phenyl groups or groups of the following structure: ##STR2## m being an integer from 1 to 5 and R is methyl group or hydrogen.
The second useful organosiloxanylalkoxy ester monomer of acrylic or methacrylic acid is represented by the following structural formula: ##STR3## n being an integer from 1 to 3; wherein, X and Y are C.sub.1 to C.sub.6 alkyl, cyclic, phenyl groups or groups of the following structure: ##STR4## m being an integer from 1 to 5 and R is methyl group or hydrogen.
The above disclosed new organosilicone monomers can be partially substituted by additional organosiloxanylalkyl ester monomers from the prior art. The first representative partial substitute organosiloxanylalkyl ester monomer of acrylic and methacrylic said from the prior art has the structural formula: ##STR5## wherein, X and Y are C.sub.1 to C.sub.6 alkyl, cyclic, phenyl groups or groups of the following structure: ##STR6## m being an integer from 1 to 6, n being an integer from 1 to 3 and R is methyl group or hydrogen.
The second useful partial substitute organosiloxanylalkyl ester monomer of acrylic and methacrylic acids is represented by the following formula: ##STR7## wherein, X and Y are C.sub.1 to C.sub.6 alkyl, cyclic, phenyl groups or groups of the following structure: ##STR8## m being an integer from 1 to 6, n being an integer from 1 to 3, A is selected from C.sub.1 to C.sub.6 alkyl, cyclic or phenyl groups, R is methyl group or hydrogen and D is hydrogen or hydroxy group.
The third useful partial substitute organosiloxanylalkyl ester monomer of acrylic and methacrylic acids is represented by the following structural formula: ##STR9## wherein, X and Y are groups of the following structure: ##STR10## m being an integer from 1 to 5, n is an integer from 1 to 3; wherein, A is selected from C.sub.1 to C.sub.6 alkyl, cyclic or phenyl groups and R is methyl group or hydrogen.
The fourth useful partial substitute organosiloxanylalkyl ester monomer of itaconic acid is represented by the following formula: ##STR11## wherein, X and Y are C.sub.1 to C.sub.6 alkyl, cyclic, phenyl groups or groups of the following structure: ##STR12## m being an integer from 1 to 5, n being an integer from 1 to 3; wherein, A is selected from C.sub.1 to C.sub.6 alkyl, cyclic or phenyl groups and Q is methyl group, hydrogen or hydroxy group.
The perfluoroalkyl ester monomers of acrylic and methacrylic acid are represented by the following formula: ##STR13## n being an integer from 1 to 3, R is methyl group or hydrogen, m being an integer from 1 to 4, a being an integer from 1 to 10 and Z is fluorine or hydrogen.
Another useful perfluoroalkyl ester monomer of the present invention is represented by the following formula: ##STR14## and telomer alcohol methacrylates or acrylates of the following formula: ##STR15## and mixtures thereof; wherein, n is an integer from 1 to 10, m is an integer from 1 to 5 and R is methyl group or hydrogen. Particularly useful in the manufacture of the lenses of the present invention are those fluoroalkyl esters selected from the group consisting of perfluoroalkylethyl acrylates and methacrylates of the following formula: ##STR16## wherein, n is an integer from 1 to 10 and R is methyl group or hydrogen.
The perfluoroalkyl ester monomers of itaconic acid useful in the present invention for the manufacturing of contact lenses are represented by the following formula: ##STR17## R is alkyl group or group of the following structure:
n being an integer from 1 to 4 and m is an integer from 1 to 10.
Additional perfluorocarbon monomers useful in the present invention to form copolymers are found in the European Patent Application No. 0084406 by David E. Rice, et al., such monomers having the following general structural formula:
wherein, m is an integer from 2 to 20, n is an integer from 2 to 30, A is selected from CF.sub.3 --, CH.sub.3 --, CH.sub.2 F--, and CF.sub.2 H--, and Z has the formula which includes one of the following: ##STR18## or mixtures thereof.
The principal sulfone monomers embodied in the present invention which contribute to the increased oxygen permeability and biocompatiability of the copolymer for contact lenses are represented by the following general formula: ##STR19## wherein, A is selected from one of the following: ##STR20## wherein, Q is C.sub.1 to C.sub.20 alkyl, perfluoroalkyl, cyclic or phenyl groups and n is an integer from 1 to 5, and organosulfone monomers having the following formula: ##STR21## wherein R.sub.1 and R.sub.2 are hydrogen, alkyl, cyclic or phenyl groups, n is an integer from 1 to 5 and m is an integer from 0 to 10.
The preferable sulfone monomers which are useful in the present invention are:
methyl vinyl sulfone,
methyl styrene sulfone,
ethyl vinyl sulfone,
ethyl styrene sulfone,
propyl vinyl sulfone,
propyl styrene sulfone,
phenyl vinyl sulfone,
phenyl styrene sulfone,
cyclohexyl vinyl sulfone,
cyclohexyl styrene sulfone,
pentyl vinyl sulfone,
pentyl styrene sulfone,
butyl vinyl sulfone,
butyl styrene sulfone,
phenoxyethyl vinyl sulfone,
phenoxyethyl styrene sulfone,
divinyl sulfone,
methacryloxyethyl methyl sulfone,
methacryloxyethyl ethyl sulfone,
methacryloxyethyl propyl sulfone,
methacryloxyethyl butyl sulfone,
methacryloxyethyl phenyl sulfone,
methacryloxyethyl pentyl sulfone,
methacryloxyethyl styrene sulfone,
2-(N ethylperfluoroalkylsulfonamido)ethylmethacrylate,
2-(N ethylperfluoroalkylsulfonamido)ethylacrylate, or mixtures thereof.
The copolymer plastic material of the present invention also incorporates hardening agents such as methyl methacrylate, ethyl methacrylate, propyl methacrylate, cyclohexyl methacrylate, glycidyl methacrylate, phenoxyethyl methacrylate, phenyl methacrylate, tetrahydrofurfuryl methacrylate, methyl acrylate, ethyl acrylate, propyl acrylate, cyclohexyl acrylate, phenoxyethyl acrylate, phenyl acrylate, tetrahydrofurfuryl acrylate, dimethyl itaconate, diethyl itaconate, dipropyl itaconate, dicyclohexyl itaconate, diphenyl itaconate, vinyl benzene (styrene), divinyl benzene or mixtures thereof.
The contact lens material is further modified by the incorporation of wettability and cross-linking agents to improve overall performance of the contact lens on the human eye. Such representative monomers of wettability agents are acrylic acid, methacrylic acid, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2,3-dihydroxypropyl acrylate, 2,3-dihydroxypropyl methacrylate, N-vinyl 2-pyrrolidinone or mixtures thereof.
Representative cross-linking agents are ethyleneglycol dimethacrylate, diethyleneglycol dimethacrylate, triethyleneglycol dimethacrylate, tetraethyleneglycol dimethacrylate, dimethacrylate siloxanyl ester monomer (PSX-563A), ethyleneglycol diacrylate, diethyleneglycol diacrylate, triethyleneglycol diacrylate, tetraethyleneglycol diacrylate, divinyl benzene, divinyl sulfone, trimethylolpropane trimethacrylate or mixtures thereof.
A variety of other ingredients may be included in the polymerization mixture so that to either enhance or provide specific properties. For example, wettability of the surface of the lens is a very important characteristic for contact lenses to possess in order to provide comfort and good visual acuity. In addition to already disclosed wettability agents named herein, additional ethylenically unsaturated monomers can also be incorporated that have a hydrophilic group such as hydroxy, carboxy, carbonamido sulfonyl, and sulfonamido groups. As an example, it can be 2-carboxyethyl acrylate, 2-carbonamidoethyl methacrylate, 2-sulfonethyl methacrylate, 2-sulfonamidoethyl acrylate, vinyl sulfonic acid, or mixtures thereof.
The preferred composition of the present invention comprises of:
(a) from about 5 to 65 weight percent of ethylenically unsaturated organosiloxanylalkoxy ester monomer of acrylic or methacrylic acid and siloxanylalkyl ester monomers of itaconic acid or mixtures thereof;
(b) from about 2 to 40 weight percent of ethylenically unsaturated perfluoralkyl ester monomer or mixtures thereof;
(c) from about 2 to 40 weight percent of ethylenically unsaturated sulfone monomer or mixtures thereof;
(d) from about 10 to 70 weight percent of hardening agent monomer (preferably, methyl methacrylate, cyclohexyl methacrylate, dimethyl itaconate) or mixtures thereof;
(e) from about 1 to 18 weight percent of difunctional cross-linking monomer (preferably triethyleneglycol dimethacrylate, tetraethyleneglycol dimethacrylate) or mixtures thereof; and
(f) from about 1 to 15 weight percent of wetting agent monomer (preferably methacrylic acid or N-vinyl 2-pyrrolidinone) or mixtures thereof.
The copolymer plastic can also be prepared without perfluoralkyl ester monomer and the material would still possess high oxygen permeability and good wettability.
The polymerization of the oxygen permeable material for the manufacture of contact lenses disclosed in the present invention is accomplished by using free-radical polymerization, such techniques are disclosed in the prior art.
Example 1
This example illustrates the preparation of tris(trimethylsiloxy)methacryloxyethoxysilane, an organosilicone monomer useful in the present invention. To a three-necked, round bottom, 12 liter flask equipped with mechanical stirrer and cooling system is added 5 liters of dry toulene, 2 moles of 2-hydroxyethylmethacrylate and 2 moles plus 10% excess of triethylamine. The flask content is cooled down to about 5.degree. C. When the temperature is reached, start addition of 2 equivalent moles of tris(trimethylsiloxy)chlorosilane; all addition takes about one hour. Then the temperature is raised to 30.degree. C. and the stirring is continued for 6 hours. After the reaction is completed, the white precipitation of triethylamine hydrochloride is filtered off; distillation of toulene proceeds at about 45.degree. C. under aspirator vacuum. The crude product is washed twice with cold water and then 2 times with 5% sodium bicarbonate solution; then the crude product is washed again 2 times with cold water. The crude product is dried over anhydrous MgSO.sub.4 for 3 hours. The MgSO.sub.4 is removed by filtration and the product is stripped under high vacuum at 75.degree. C. The refractive index n.sub.D.sup.25 is 1.4112.+-.0.001; the infrared spectrum confirmed the structure. The same procedure is used for the preparation of tris(pentamethyldisiloxanyl)methacryloxyethoxysilane, bis(pentamethyldisiloxanyl)trimethylsiloxanylmethacryloxyethoxysilane, and bis(trimethylsiloxy)pentamethyldisiloxanylmethacryloxyethoxysilane if the starting material tris(trimethylsiloxy)chlorosilane is replaced with pentamethylchlorosilane and trimethylchlorosilane in the desired molar ratio.
Example 2
This example illustrates the preparation of the representative perfluoroalkyl ester monomer useful in the present invention. A 12 liter, 3-necked, round bottom flask equiped with a mechanical stirrer and cooling system is charged with 5 liters of toulene, 3 moles of 1,1',2,2'-tetrahydroperfluorohexylethanol and 3 moles plus 10% excess of triethylamine. The flask content while stirring is cooled down to about 5.degree.-10.degree. C. until the temperature is reached, then start addition of 1 mole of trichloromethacryloxypropylsilane; all addition takes about one hour. When all addition is completed the temperature of the reaction mixture is raised to 30.degree. C. and stirring is continued for 10 hours. After the reaction is completed, white precipitation of triethylamine hydrochloride is filtered off; distillation of toulene proceeds at about 45.degree. C. under aspirator vacuum. The crude product is washed twice with cold water, then 2 times with 5% sodium bicarbonate solution and then the crude product is washed again 2 times with cold water. The crude product is dried over anhydrous MgSO.sub.4 for 3 hours; the MgSO.sub.4 is removed by filtration and the product is stripped under high vacuum at 75.degree. C. The monomer is then ready to be used in the polymerization process. Many additional tris(perfluoroalkylethoxy)methacryloxypropylsilanes can be prepared by this chemistry.
Example 3
This example is an illustration of the preparation of 2,3-di[tris(trimethylsiloxy)siloxanyl]methacryloxypropane. The 12 liter flask equipment with a mechanical stirrer, additional funnel and cooling system is charged with 5 liters of toulene, 2 moles of 2,3-dihydroxypropylmethacrylate and 2 moles plus 10% excess of triethylamine. The contents of the flask is cooled down to 5.degree. C., then addition of 2 moles of tris(trimethylsiloxy)chlorosilane proceeds in about a period of one hour. When all addition is completed the temperature of the reaction mixture is elevated to 30.degree. C. and stirring is continued for about 8 hours. After the reaction is completed, white precipitation of triethylamine hydrochloride is filtered off; distillation of toulene proceeds at about 45.degree. C. under aspirator vacuum. The crude product is washed twice with cold water and 2 times with 5% sodium bicarbonate solution and then the crude product is washed again 2 times with cold water. The crude product is dried over anhydrous MgSO.sub.4 for 3 hours; the MgSO.sub. 4 is removed by filtration and the product is stripped under high vacuum at 75.degree. C. The refractive index of the product is 1.4083.+-.0.002. The same procedure is used for the preparation of 2,3-di(pentamethyldisiloxanyl)methacryloxypropane if the starting material tris(trimethylsiloxy)chlorosilane is replaced with pentamethylchlorodisiloxane.
Example 4
This example illustrates the preparation of representative copolymer material for contact lenses. To a 200 ml flask is added 35 grams of organosilicone monomer previously prepared in Example 1, tris(trimethylsiloxy)methacryloxyethoxysilane, 15 grams of 2,3-di[tris(trimethylsiloxy)siloxanyl]methacryloxypropane, 2 grams of methacrylate dimer (PSX-563A), 10 grams of cyclohexyl methacrylate, 5 grams of methacrylic acid, 2.5 grams of N-vinyl 2-pyrrolidinone, 5 grams of perfluoro monomer prepared in Example 2, 10 grams of triethyleneglycol dimethacrylate, 14 grams of methyl methacrylate, 5 drops of D&C #6 color dye, 0.5 ml of t-butyl peroxypivalate and 0.2 grams of benzoyl peroxide. All contents are mixed thoroughly and poured into polypropylene tubes, molds or sililated glass tubes, closed and polymerized in water bath at 40.degree. C. for a period of about 18 hours. The rods are then put into a thermostated oven for at least 24 hours, having a temperature of about 100.degree. C. The copolymer plastic is transparent, hard and suitable for the machining of highly permeable contact lenses.
Example 5
This example illustrates the preparation of representative copolymer plastic material for contact lenses made only from siloxanyl monomer as a source of oxygen permeability. To the 200 ml flask is added 41 grams of 2,3,-di[tris(trimethylsiloxy)siloxanyl]methacryloxypropane, 10 grams of cyclohexyl methacrylate, 4.5 grams of methacrylic acid, 5 grams of diethyleneglycol dimethacrylate, 39 grams of methyl methacrylate, 0.4 grams of t-butyl peroxyoctoate and 0.1 grams of benzoyl peroxide, all components are mixed thoroughly and poured into polypropylene tubes, molds or sililated glass tubes closed with stoppers and polymerized in a water bath or thermostated oven set at 45.degree. C. for a period of about 20 hours. The rods or blanks are then put into a thermostated oven preheated at 105.degree. C. for a period of 24 hours. The copolymer plastic is transparent, hard, oxygen permeable, wettable and suitable for manufacturing oxygen permeable contact lenses.
Example 6-13
This example illustrates the preparation of optically clear plastic prepared in accordance with the polymerization procedure described in Example 5, except the amounts and kinds of monomers may be different as shown in the following table:
Example 14
This example illustrates the preparation of oxygen permeable copolymer plastic for contact lenses made from siloxanylalkoxy ester monomer and perfluoroalkyl ester monomer as a source of oxygen permeability. To a 200 ml flask is added 35 parts of bis(pentamethyldisiloxanyl)trimethylsiloxymethacryloxyethoxysilane, 15 parts of cyclohexyl methacrylate, 10 parts of tris(1,1'-dihydroperfluorohexyloxy)methacryloxypropylsilane, 3 parts of N-vinyl 2-pyrrolidinone, 7 parts of tetraethyleneglycol dimethacrylate, 5 parts of methacrylic acid, 25 parts of methyl methacrylate, 0.5 parts of t-butyl peroxypivalate and 0.2 parts of benzoyl peroxide; the polymerization is carried out by the same procedure as described in Example 5. The resulting plastic is transparent, hard, stable, wettable and suitable for machining of highly permeable contact lenses.
Example 15-22
Samples of optically clear plastic are prepared in accordance with the polymerization procedure described in Example 14, except the amounts and kinds of components may be different, as shown in the following table;
Example 23
This example illustrates the preparation of oxygen permeable copolymer plastic for contact lenses from siloxanylalkoxy ester of methacrylic acid and sulfone monomer as a source of oxygen permeability; consisting of 40 parts of tris(trimethylsiloxy)methacryloxyethoxysilane, 10 parts of cyclohexyl methacrylate, 8 parts of methyl vinyl sulfone, 20 parts of tetrahydrofurfuryl methacrylate, 5 parts of 2-hydroxyethyl methacrylate, 7 parts of N-vinyl 2-pyrrolidinone, 7 parts of methyl methacrylate and 0.4 parts of t-butyl peroxypivalate are polymerized. The resulting copolymer plastic has a hardness of 86.+-.2 as measured on the Shore D (ASTM-2440) hardness tester.
Example 24
A contact lens has been manufactured from the oxygen permeable material of the present invention using standard, conventional manufacturing techniques known in the art. The base curve of the lens was cut at 7.80 mm, the front curve of the lens was cut at 8.21 mm, the center thickness of the lens was 0.19 mm. The contact lens was then polished using a technique widely known in the contact lens industry. The base curve of the lens was 7.81 mm; after the lens was polished the base curve remained at 7.81 mm. The lens was soaked over 72 hours in Soaclens solution and the base curve remained at 7.81 mm.
Example 25-32
Samples of optically clear plastic are prepared in accordance with the polymerization procedure described in Example 4, except the amounts and kinds of components may be different as shown in the following table:
Example 33
The polymerization of a mixture of 20 parts of 2,3-di[tris(trimethylsiloxy)siloxanyl]methacryloxypropane, 20 parts of tris(trimethylsiloxy)methacryloxypropylsilane, 10 parts of bis(1,1',5-trihydroperfluoropentyl)itaconate, 10 parts of cyclohexyl methacrylate, 8 parts of ethyleneglycol dimethacrylate, 4 parts of methacrylic acid, 3 parts of N-vinyl 2-pyrrolidinone and 25 parts of methyl methacrylate are polymerized by using free-radical catalysts, as shown in Example 5, in polypropylene base curve premolded caps. The resulting plastic gives a transparent, concave plug.
Example 34
The polymerization procedure of Example 5 is repeated, except the amounts and kinds of components in the polymerization are changed as follows: 45 parts of tris(trimethylsiloxy)siloxanylmethacryloxyethoxysilane, 10 parts of tris(1,1',2,2'-tetrahydroperfluoropentyloxy)methacryloxypropylsilane, 10 parts of cyclohexyl methacrylate, 9 parts of triethyleneglycol dimethacrylate, 5 parts of methacrylic acid, 3 parts of N-vinyl 2-pyrrolidinone and 18 parts of methyl methacrylate are polymerized by using free-radical initiator at 47.degree. C. The plastic is then removed from the molds, transferred into a thermostated oven which is set at 108.degree. C. and the copolymer plastic is cured for an additional 24 hours. The resulting plastic has an oxygen permeability of about 91.times.10.sup.-11 (cm.sub.2 /sec)(ml O.sub.2 /ml.times.mm Hg) at 35.degree. C., as analyzed on the Schema-Versatae Model #920 instrument (an analytical technique widely used in the industry).
Example 35
The polymerization procedure of Example 5 is repeated, except the amounts and kinds of components in the polymerization are changed as follows: 35 parts of tris(trimethylsiloxy)siloxanylmethacryloxypropylsilane, 20 parts of tris(perfluoroalkylethoxy)methacryloxypropylsilane (which can be prepared by chemistry disclosed in Example 2), 15 parts of cyclohexylmethacrylate, 10 parts of triethyleneglycol dimethacrylate, 6 parts of methacrylate acid and 3 parts of N-vinyl pyrrolidinone which are polymerized using free-radical initiator in suitable polypropylene molds in constant temperature water bath at 45.degree. C. for about 24 hours; the plastic is then removed from the water bath and placed in thermostated oven preheated to 105.degree. C., where the process of final polymerization proceeds over a 24 hour period. The resulting plastic is removed, cut to the shape of a contact lens by conventional technique known in the contact lens industry and machined to a prescription contact lens of high oxygen permeability.
Example 36
The polymerization procedure of Example 5 is repeated, except the amounts and kinds of components in the polymerization are changed as follows: 35 parts of tris(hydrodimethylsiloxy)methacryloxypropylsilane, 20 parts of tris(perfluoroalkylethoxy)methacryloxypropylsilane (which can be prepared the same as in Example 2), 15 parts of cyclohexyl methacrylate, 10 parts of triethyleneglycol dimethacrylate, 6 parts of methacrylic acid and 3 parts of N-vinyl 2-pyrrolidinone are polymerized using a free-radical initiator in suitable polypropylene molds in a constant temperature water bath at 45.degree. C. for about a 24 hour period; the plastic is then removed from water bath and placed in thermostated oven preheated to 105.degree. C. The process of final polymerization proceeds within a 24 hour period. The resulting plastic is removed, cut to the shape of a contact lens by the conventional technique known in the contact lens industry and machined to a prescription contact lens of high oxygen permeability.
Example 37
The polymerization of a mixture of 20 parts of tris(trimethylsiloxy)methacryloxyethoxysilane, 20 parts of 2-(N ethylperfluoroalkylsulfonamido)ethylmethacrylate, 10 parts of tris(trimethylsiloxy)methacryloxypropylsilane, 10 parts of cyclohexyl methacrylate, 8 parts of ethyleneglycol dimethacrylate, 4 parts of methacrylic acid, 3 parts of N-vinyl 2-pyrrolidinone, and 25 parts of methyl methacrylate are polymerized by using a free-radical catalyst, as shown in Example 5, in polypropylene base curve premolded caps. The resulting plastic gives a transparent, concave plug suitable for the manufacture of an oxygen permeable contact lens.
Claims
The embodiments of the invention which are claimed as an exclusive property or priviledge are defined as follows:
1. An ophthlamic device formed of a copolymer plastic material which comprises: from about 5 to about 65 weight percent of at least one organosiloxanylalkoxy ester monomer selected from the group consisting of (1) an organosiloxanylalkoxy ester monomer of acrylic or methacrylic acid which is represented by the following structural formula: ##STR22## wherein X and Y are C.sub.1 to C.sub.6 alkyl, phenyl or groups of the following structure: ##STR23## A is C.sub.1 -C.sub.6 alkyl or phenyl, m being an integer from 1 to 5 and R is methyl or hydrogen; and, (2) an organosiloxanylalkoxy ester monomer of acrylic or methacrylic acid represented by the following structural formula: ##STR24## n being an integer from 1 to 3, wherein A, X, Y, R and m are as defined above; which are copolymerized with from about 2 to 40 weight percent of at least one perfluoroalkyl ester monomer selected from the group consisting of perfluoroalkyl ester monomers of acrylic or methacrylic acid, said perfluoroalkyl ester monomer having the following structural formula: ##STR25## wherein R and n are as defined above, d being an integer from 1 to 4, a being an integer from 1 to 10 and z is selected from the group consisting of fluorine, hydrogen and mixtures thereof; which are copolymerized with from about 2 to 40 weight percent of at least one organosulfone monomer selected from the group consisting of an organosulfone monomer having the following structural formula: ##STR26## wherein R.sub.1 is selected from one of the following ##STR27## wherein Q is C.sub.1 to C.sub.20 alkyl, perfluoroalkyl or phenyl and g is an integer from 1 to 5; said copolymer plastic material including from about 10 to 70 weight percent of at least one hardening agent monomer, said hardening agent selected from the group consisting of alkyl ester monomers of acrylic, methacrylic and itaconic acid and mixtures thereof; namely, phenyl methacrylate, tetrahydrofurfuryl methacrylate, methyl acrylate, ethyl acrylate, propyl acrylate, cyclohexyl acrylate, phenoxyethyl acrylate, phenyl acrylate, tetrahydrofurfuryl acrylate, dimethyl itaconate, diethyl itaconate, dipropyl itaconate, dicylohexyl itaconate, diphenyl itaconate, vinyl benzene (styrene), divinyl benzene and mixture thereof; said copolymer plastic material further including from about 1 to 15 weight percent of at least one wettability agent selected from the group consisting of methacrylic acid, acrylic acid, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2,3-dihydroxypropyl acrylate, 2,3-dihydroxypropyl methacrylate, N-vinyl 2-pyrrolidinone and mixtures thereof; said copolymer plastic including from about 1 to 18 weight percent of at least one difunctional cross-linking monomer selected from the group consisting of ethyleneglycol dimethacrylate, diethyleneglycol dimethacrylate, triethyleneglycol dimethacrylate, tetraethylene glycol dimethacrylate, dimethacrylate siloxanyl ester monomer ethyleneglycol diacrylate, tetraethyleneglycol diacrylate, divinyl benzene, divinyl sulfone, trimethylolpropane trimethacrylate and mixtures thereof.
2. An ophthalmic device which is manufactured from oxygen permeable copolymer plastic material which comprises from about 5 to about 65 weight percent of at least one organosilicone monomer selected from the group consisting of (1) an ethylenically unsaturated organosiloxanylalkoxy ester monomer of acrylic or methacrylic acid having the following formula: ##STR28## wherein X and Y are C.sub.1 to C.sub.6 alkyl, phenyl or groups of the following structure: ##STR29## A is C.sub.1 -C.sub.6 alkyl or phenyl, m being an integer from 1 to 5 and R is methyl or hydrogen; and (2) an organosiloxanylalkoxy ester monomer of acrylic or methacrylic acid having the following structural formula: ##STR30## n being an integer from 1 to 3, wherein A, X, Y, R and m are as defined above; which is copolymerized with from about 2 to 40 weight percent of at least one perfluoroalkyl ester monomer selected from the group consisting of (1) a perfluoroalkyl ester monomer of acrylic or methacrylic acid or mixtures thereof having the following structural formula: ##STR31## wherein R and n are as defined above, d being an integer from 1 to 4, a being an integer from 1 to 10 and Z is flourine or hydrogen; (2) a perfluorocarbon ester monomer of the following structural formula: ##STR32## wherein h is an integer from 1 to 10, g is an integer from 1 to 5 and R is as defined above; (3) a perfluoroalkylester monomer of itaconic acid having the following structural formula: ##STR33## R.sub.1 is alkyl or a group of the following structure j being an integer from 1 to 4 and k is an integer from 1 to 10; and mixtures thereof.
3. An ophthalmic device formed of a copolymer plastic material which comprises: from about 5 to about 65 weight percent of at least one organosilicone selected from the group consisting of (1) an organosiloxanylalkoxy ester monomer of acrylic or methacrylic acid which has the structural formula: ##STR34## wherein X and Y are C.sub.1 to C.sub.6 alkyl, phenyl or groups of the following structure: ##STR35## A is C.sub.1 to C.sub.6 alkyl or phenyl, m being an integer from 1 to 5 and R is methyl or hydrogen; (2) an organosiloxanylalkoxy ester monomer of acrylic or methacrylic acid having the following structural formula: ##STR36## n being an integer from 1 to 3, wherein A, X, Y, R and m are as defined above; (3) an ethylenically unsaturated organosiloxanylalkyl ester monomer chosen from those having the following structural formula: ##STR37## wherein A.sub.1, X.sub.1 and Y.sub.1 are C.sub.1 to C.sub.6 alkyl, cyclohexyl, phenyl or groups of the following structure: ##STR38## wherein A and R are as defined above, t being an integer from 1 to 6, and n being an integer from 1 to 3; (4) an organosiloxanylalkyl ester monomer of acrylic or methacrylic acid having the following formula: ##STR39## wherein A.sub.2, X.sub.2 and Y.sub.2 are C.sub.1 to C.sub.6 alkyl, cyclohexyl, phenyl or groups of the following structure: ##STR40## wherein A, R, t and n are as defined above, and D is hydrogen or hydroxy; (5) an organosiloxanylalkyl ester monomer of acrylic or methacrylic acid having the following formula: ##STR41## wherein X.sub.3 and Y.sub.3 are groups of the following structure: ##STR42## wherein R.sub.1, m and n are as defined above and A.sub.3 is selected from the group consisting of C.sub.1 to C.sub.6 alkyl, cyclohexyl and phenyl; (6) an organosiloxanylalkyl ester monomer of itaconic acid having the following structural formula: ##STR43## wherein X.sub.4 and Y.sub.4 are selected from the group consisting of C.sub.1 to C.sub.6 alkyl, cyclohexyl and phenyl, or groups of the following structure: ##STR44## wherein A.sub.3, m and n are as defined above and E is methyl or hydrogen; which is copolymerized with an organosulfone monomer having the general structural formula: ##STR45## wherein R.sub.2 and R.sub.3 are selected from the group consisting of hydrogen, alkyl, and phenyl, u is an integer from 1 to 5 and v is an integer from 0 to 10; which are copolymerized with at least one hardening agent monomer selected from the group consisting of methyl methacrylate, ethyl methacrylate, propyl methacrylate, cyclohexyl methacrylate, glycidyl methacrylate, phenoxyethyl methacrylate, phenyl methacrylate, tetrahydrofurfuryl methacrylate, methyl acrylate, ehtyl acrylate, phenyl acrylate, tetrahydrofurfuryl acrylate, dimethyl itaconate, diethyl itaconate, dipropyl itaconate, dicyclohexyl itaconate, diphenyl itaconate, vinyl benzene (styrene), divinyl benzene and mixtures thereof.
4. An ophthalmic device which is manufactured from oxygen permeable copolymer plastic material, said plastic comprising an organosiloxanylalkoxy ester monomer of acrylic and methacrylic acid which is represented by the following formula: ##STR46## wherein X and Y are C.sub.1 to C.sub.6 alkyl, phenyl or groups of the following structure: ##STR47## A being C.sub.1 to C.sub.6 alkyl or phenyl, m being an integer from 1 to 5 and R is methyl or hydrogen; and an organosiloxanylalkoxy ester monomer of acrylic or methacrylic acid represented by the following structural formula: ##STR48## wherein A, X, Y, R and m are as defined above and n being an integer from 1 to 3, and perfluoroalkyl ester monomers of acrylic or methacrylic acid, said perfluoroalkyl ester monomer having the following formula: ##STR49## wherein R and n are as defined above, d being an integer from 1 to 4, a being an integer from 1 to 10 and Z being flourine or hydrogen.
5. The ophthlamic device of claim 2 in the form of an oxygen permeable contact lens, wherein said lens is modified by incorporation from about 2 to 30 weight percent of perfluoroalkyl ester monomers of acrylic, methacrylic or itaconic acid or mixtures thereof.
6. A contact lens material comprising from about 5 to 65 weight percent of organosiloxanylalkoxy ester monomers of acrylic or methacrylic acid, namely 2,3-di[tris(trimethylsiloxy)siloxanyl]methacryloxypropane, tris(trimethylsiloxy)methacryloxyethoxysilane, 2,3-di[tris(trimethyxlsiloxy)siloxanyl]acryloxypropane, tris(trimethylsiloxy)acryloxyethoxysilane, 2,3-di(pentamethyldisiloxanyl)methacryloxypropane, tris(pentamethyldisiloxanyl)methacryloxyethoxysilane, bis(pentamethyldisiloxanyl)trimethylsiloxanylmethacryloxyethoxysilane, bis(trimethylsiloxy)pentamethyldisiloxanylmethcaryloxyethyoxysilane and from about 2 to 30 weight percent of perfluoroalkyl monomers of methacrylic, acrylic or itaconic acid or mixtures thereof and from about 10 to 60 weight percent of hardening agents, such as methyl methacrylate, ethyl methacrylate, propyl methacrylate, cyclohexyl methacrylate, glycidyl methacrylate, phenoxyethyl methacrylate, phenyl methacrylate, tetrahydrofurfuryl methacrylate, methyl acrylate, ethyl acrylate, propyl acrylate, cyclohexyl acrylate, phenoxyethyl acrylate, phenyl acrylate, tetrahydrofurfuryl acrylate, dimethyl itaconate, diethyl itaconate, dipropyl itaconate, dicyclohexyl itaconate, diphenyl itaconate, vinyl benzene (styrene), divinyl benzene and equivalents; said contact lens material is modified to be wettable by incorporation of one or more wettability agent such as acrylic acid, methacrylic acid, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2,3-dihydroxypropyl acrylate, 2,3-dihydroxypropyl methacrylate, or N-vinyl 2-pyrrolidinone or mixtures thereof; said contact lens material also embodies cross-linking agents such as ethyleneglycol dimethacrylate, diethyleneglycol dimethacrylate, triethyleneglycol dimethacrylate, tetraethylene glycol dimethacrylate, dimethacrylate siloxanyl ester monomer (PSX-563A), ethyleneglycol diacrylate, tetraethyleneglycol diacrylate, divinyl benzene, divinyl sulfone, and trimethylolpropane trimethacrylate or mixtures thereof.
7. An oxygen permeable contact lens material of claim 3 wherein said material is modified by incorporation from about 2 to 30 weight percent of perfluoroalkyl ester monomer of acrylic, methacrylic and itaconic acid or mixtures thereof.
8. The ophthlamic device of claim 1 wherein the about 5 to 65 weight percent of organosiloxanylalkoxy ester monomers of acrylic and methacrylic acid are selected from the group consisting of 2,3-di[tris(trimethylsiloxy)siloxanyl]methacryloxypropane, tris(trimethylsiloxy)methacryloxyethoxysilane, 2,3-di[tris(trimethylsiloxy)acryloxyethoxysilane, 2,3-di(pentamethyldisiloxanyl)methacryloxypropane, tris(pentamethyldisiloxanyl)methacryloxyethoxysilane, bis(pentamethyldisiloxanyl)trimethylsiloxanylmethacryloxyethoxysilane and bis(trimethylsiloxy)pentamethyldisiloxanylmethacryloxyethoxysilane and the perfluoroalkyl ester monomer is present in the amount of from about 2 to 30 weight percent of a perfluoroalkyl monomer of methacrylic, acrylic and itaconic acid or mixtures thereof; and includes from about 5 to 40 weight percent of hardening agents, selected from the group consisting of methyl methacrylate, ethyl methacrylate, propyl methacrylate, cyclohexyl methacrylate, glycidyl methacrylate, phenoxyethyl methacrylate, phenyl methacrylate, tetrahydrofurfuryl methacrylate, methyl acrylate, ethyl acrylate, propyl acrylate, cyclohexyl acrylate, phenoxyethyl acrylate, phenyl acrylate, tetrahydrofurfuryl acrylate, dimethyl itaconate diethyl itaconate, dipropyl itaconate, dicyclohexyl itaconate, diphenyl itaconate, vinyl benzene (styrene), divinyl benzene and mixtures thereof; said copolymer plastic material being modified to be wettable by incorporation of at least one wettability agent selected from the group consisting of acrylic acid, methacrylic acid, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2,3-dihydroxypropyl acrylate, 2,3-dihydroxypropyl methacrylate, N-vinyl 2-pyrrolidinone and mixtures thereof; said copolymer plastic material additionally including at least one cross-linking agent selected from the group consisting of ethyleneglycol dimethacrylate, diethyleneglycol dimethacrylate, triethyleneglycol dimethacrylate, tetraethyleneglycol dimethacrylate, dimethacrylate siloxanyl ester monomer (PSX-563A), ethyleneglycol diacrylate, tetraethyleneglycol diacrylate, divinyl benzene sulfone, trimethylolpropane trimethacrylate and mixtures thereof.