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GB2456002A - A method for the manufacture of silicone hydrogel contact lenses in which filler material is introduced, the lens formed and the filler extracted. - Google Patents

A method for the manufacture of silicone hydrogel contact lenses in which filler material is introduced, the lens formed and the filler extracted. Download PDF

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Publication number
GB2456002A
GB2456002A GB0725331A GB0725331A GB2456002A GB 2456002 A GB2456002 A GB 2456002A GB 0725331 A GB0725331 A GB 0725331A GB 0725331 A GB0725331 A GB 0725331A GB 2456002 A GB2456002 A GB 2456002A
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United Kingdom
Prior art keywords
lens
filling material
silicone
contact lens
material comprises
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Withdrawn
Application number
GB0725331A
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GB0725331D0 (en
Inventor
William M Hung
Chih-Hun Chang
Chih-Chin Lian
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Individual
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Individual
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Priority to GB0725331A priority Critical patent/GB2456002A/en
Publication of GB0725331D0 publication Critical patent/GB0725331D0/en
Publication of GB2456002A publication Critical patent/GB2456002A/en
Withdrawn legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29DPRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00Producing optical elements, e.g. lenses or prisms
    • B29D11/00009Production of simple or compound lenses
    • B29D11/00038Production of contact lenses
    • B29D11/00076Production of contact lenses enabling passage of fluids, e.g. oxygen, tears, between the area under the lens and the lens exterior
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/20Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored
    • B29C67/202Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored comprising elimination of a solid or a liquid ingredient
    • GPHYSICS
    • G02OPTICS
    • G02CSPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00Optical parts
    • G02C7/02Lenses; Lens systems ; Methods of designing lenses
    • G02C7/04Contact lenses for the eyes

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  • Health & Medical Sciences (AREA)
  • Ophthalmology & Optometry (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Eyeglasses (AREA)

Abstract

A method for forming a silicone hydrogel contact lens comprises the steps of mixing silicone lens materials with a filler, curing the lens material to form a lens body and extracting whole or part of the filling material to form the finished lens. The filling material is a non polymerizable, water soluble surfactant. All of the described embodiments disclose Dow Corning (RTM) 5329 as the filler material. An independent apparatus claim specifies silicone hydrogel contact lenses containing densely distributed and interconnected pores.

Description

TITLE: METHOD FOR FORMII'TG SILICONE HYDROGEL CONTACT
LENS AND STRUCTURE THEREOF
BACKGROUND OF THE INVENTION
(a) Technical Field of the invention
The present invention relates to a method for forming a silicone hydrogel contact lens and the structure of the contact lens formed with the method, and in particular to a method for making a silicone hydrogel contact lens that may allow for wearing of extended time without causing any eye disease or discomfort, as well as the structure of the contact lens so made.
(b) Description of the PriorArt
Due to the needs in the respects of aesthetics and convenience, contact lenses are getting popular recently. There are generally two categories of contact lenses, namely hard contact lenses and soft contact lenses, between which the soft contact lens is more comfortable in wearing. Figure 1 of the attached drawings shows a conventional structure of contact lens, broadly designated at 10. To wear the conventional contact lens 10, the wearer inserts the contact lens 10 into his or her eye with the contact lens 10 located immediately in front of the eyeball 3. The contact lens 10 then serves to refract the light enters the eyeball to thereby correct the vision of the wearer.
The contact lens 10 is tightly positioned on the surface of the eyeball, that prevents air from reaching the eyeball during the period in which the contact lens is worn. Lack of oxygen supply to the eye, may cause eye redness (expansion of eye capillary) of the contact lens wearer and thus extreme discomfort. In respect of this, it is of vital importance to the eye cells that the contact lens material has high oxygen permeability. Otherwise, wearing contact lens with extended period of time will eventually result in death of eye cells and causing eye diseases due to lacking of oxygen supplied to the cells.
The most common lens materials that are currently available for making soft contact lens include silicone and hydrogel, both having advantages and disadvantages. The hydrogel is a hydrophilic substance, but possesses only low oxygen permeability. Furthermore, hydrogel with high water content would lose part of water in a dry environment, causing discomfort to the wearer of the contact lens.
On the other hand, silicone material, which possessing excellent oxygen permeability, is hydrophobic, incapable of conveying nutrient fluid and expelling wastes. Furthermore, a contact lens made of a material that is not wettable, such as silicone, may undesirably suck to the eyeball, making it difficult to remove from the eye, and eventually damage the eye.
Therefore, polymeric silicone hydrogel materials become the material of choice for the new generation of contact lenses, as described in US Patent Nos. 4,136,250, 4,139,513, 4,153,641, 4,260,725, 4,711,943, 4,740,533, 4,910,277, 4,983,702, 5,034,461, 5,070,169, 5,070,215, 5,093,447, 5,260,000, 5,426,158, 5,710,302, 5,714,557, 5,726,733, 5,908,906, 5,959,117, 5,962,548, 6,367,929, 6,822,016, 6,849,671, 6,891,010, 7,052,131, and 7,098,282. Silicone hydrogel materials, have the advantages of both above materials mentioned. This is due to the fact that required macromers contained both silicone and hydrogel blocks, the silicone portion (or a fluorine contained silicone) provides high oxygen pemieability, while the hydrogel portion provides the wettability, that facilitates fluid tiansport and lens movement. Unfortunately, the process of making this type of macromers are extreme difficult and thus costly. Since it is difficult to mix together two substances with totally opposite properties, while still maintaining optical clarity of the final mixture. It is just as difficult as mixing water with oil in an attempt to form a clear and completely light transparent film. The copolymerization of these monomers (or macromers) generally results in opaque, phase-separated materials.
Thus, notwithstanding the advances made to date, there still exists a need a new method to manufacture silicone hydrogel lens which possess a high degree of oxygen permeability and wettability. It may allow to use as extended wear contact lens without further surface treatment.
SUMMARY OF THE INVENTION
The principal objective of the present invention is to provide a simple method for making silicone hydrogel contact lens, the simplified process would effectively reduces manufacturing costs and enhance market competitiveness.
Another objective of the present invention is to provide a silicone hydrogel contact lens that posses a high degree of oxygen permeability and wettability. It may allow to use as extended wear contact lens without further surface treatment.
In accordance with the present invention, a method for forming silicone hydrogel contact lens comprises a mixing step for mixing silicone lens material (matrix) with filling materials to form a uniform mixture, a lens forming step for curing the mixture to form a lens body, and an extracting step for removing part or whole filling materials to form the silicone hydrogel lens.
The lens body so made in accordance with the present invention comprises densely distributed and interconnected pores within the lens body and on surfaces of the lens body.
The foregoing object and sumrnaiy provide only a brief introduction to the present invention. To fully appreciate these and other objects of the present invention as well as the invention itself, all of which will become apparent to those skilled in the art, the following detailed description of the invention and the claims should be read in conjunction with the accompanying drawings. Throughout the specification and drawings identical reference numerals refer to identical or similar parts.
Many other advantages and features of the present invention will become manifest to those versed in the art upon making reference to the detailed description and the accompanying sheets of drawings in which a preferred structural embodiment incorporating the principles of the present invention is shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a schematic view of a contact lens; Figure 2 is a flow chart illustrating a method for fonning a silicone hydrogel contact lens in accordance with the present invention; and Figure 3 is a schematic view illustrating an illustrative example of a contact lens made with the method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following descriptions are of exemplary embodiments only, and are not intended to limit the scope, applicability or configuration of the invention in any way. Rather, the following description provides a convenient illustration for implementing exemplary embodiments of the invention.
Various changes to the described embodiments may be made in the ftuiction and arrangement of the elements described without departing from the scope of the invention as set fbrth in the appended claims.
With reference to the drawings and in particular to Figures 2 and 3, the present invention provides a method for forming a silicone hydrogel contact lens and the method comprises a mixing step 11, a lens forming step 12, and an extracting step 13. The mixing step 11 mixes lens monomers (or macromers) with the filling materials. The filling materials are not polymerizable but water soluble, such as a water soluble (or organic solvent soluble) silicon-contained surfactant or a water soluble silicone, that serves as a filler, then mix with polymerizable silicone lens material to form a uniform mixture substance. In the lens forming step 12, the lens mixture is processed with standard polymerization methods to form a cleai; soft, and resilient lens body 1. In the extracting step 13, the water soluble filling material is extracted or removed from the silicone matrix of the lens body 1.
in this way, the lens body I is constituted with silicone hydrogel matrix and contain densely distributed and interconnected pores 2 inside the silicone hydrogel matrix. These pores can later be filled with saline solution or tear.
In accordance with the present invention, the silicone hydrogel contact lens is made by mixing a water soluble filling material with a silicone lens material to form the lens 1, then the water soluble filling material is removed from the lens matrix by simple water (or solvent) extraction to form the final product of the lens 1. Thus, in accordance with the present invention, plasma processing in not always necessary and there is no bottle neck in the manufacturing process in accordance with the present invention. As a result, manufacturing costs are reduced and market competitiveness is enhanced.
The polymerization process that the raw material of the contact lens in accordance with the present invention is subjected to for making the contact lens 1 can be any suitable polymerization process, such as thermal polymerization or IJV (ultraviolet) radiation polymerization. Initiator for thermal polymerization of the present invention includes, but not limited to, lauroyl peroxide, isopropyl percarbonate, and azobisisobutyronitrile, which initiates polymerization process by generating free radicals in suitable high temperatures. On the other hand, initiators for photo polymerization applicable in the present invention include, but not limited to, aromatic aipha-hydroxyketone or tertiary amine with diketone.
Additives can be added into the lens material of the silicone hydrogel contact lens of the present invention, such as UV light absorbents and dyes.
Other chemicals, such as mold release agent and wetting agent, can also be added to improve the manufacturing process of the contact lens.
EXAMPLE I
Following chemicals are mixed to form a clear solution, which will be referred as Chemical I: methacryloxy propyl tris(trimethy siloxysilane) (TRIS) 47 parts; methyl methacrylate (MIvIA) 8 parts; N,N-dimethylaciylamide (DMAA) 42 parts; hydroxyethylrnethacrylate (HEIVIA) 2 parts; ethylene glycol dirnethacrylate (EGDMA) 1.5 parts; and 2,2'-azobis(2,4-dirnethylvaleronitrile) (ADVN) 1 part.
The solution of Chemical I is filled into the contact lens mold and a standard thermal polymerization process is carried out to form the lens.
After de-molding, the lens is socked in water overnight and then kept in saline. The lens so formed is optically clear, but the lens is rigid and hydrophobic, therefore it cannot be used as a soft contact lens.
On the othei-hand, when mixing 86.6% of Chemical I with 19.4% of Dow Coming 5329, a clear solution was resulted. A contact lens made with the same process as described in the EXAMPLE 1 above, is optically clear and hydrophilic. The contact lens so made has water content of around 29%.
EXAMPLE 2
Following chemicals are mixed to form a clear solution, which will be referred as Chemical II: methacryloxy propyl tris(trimethy siloxysilane) (TRIS) 45.5 parts; methyl methacrylate (MMA) 8 parts; N,N-dirnethylaciylamide (DMAA) 32 parts; 1,1,1,3,3,3 -hexafluoroisopropyl acrylate 10.5 parts; ethylene glycol dimethacrylate (EGDMA) 4 parts; and 2,2 -azobis(2,4-dimethylvaleronitrile) (ADVN) 2.5 parts.
A contact lens was made by carrying out the same process as described in the EXAMPLE I above with Chemical 11, is optically clear, however the lens is rigid and hydrophobic, therefore it cannot be used as a soft contact lens.
However, if a clear solution, hereinafter referred to as Chemical III, which is formed by unifornily mixing 4 parts of Chemical II with one part of Dow Coming 5329, is used to make a contact lens with the same process as described in the EXAMPLE I above, then the contact lens so made is optically clear and hydrophilic. The contact lens so made has water content of around 18%.
If desired, few drops of Blue-15 solution was added into the Chemical rn to fonn a light bluish transparent liquid (IV) and such a light bluish liquid is used to form a contact lens with the same process as described in the EXAMPLE I above. The contact lens so made has a light bluish color. It is noted that Blue-IS solution mentioned above is a liquid formed by dispersing Blue-15 paste at a concentration of 5% in N,N-dimethylaciylamide.
Furthermore, by adding 2.2% 2-(4-benzoyl-3-hydroxyphenoxy) ethylactylate into the above mentioned liquid IV, the resulting mixture is then used to make a contact lens with the same process as described in the EXAMPLE 1 above. The contact lens so made is optically clear and can block more than 90% UV radiation.
A process for making a co'ored cosmetic contact lens is as follows. The blue printing ink was prepared by mixing a proper amount of Blue-15 with Chemical III, then adding 5% of trimethyloipropane trimethacrylate to make the final mixture. The blue printing ink is fllst printed in a lens mold to form a desired pattern, then the coating was heated to half-cure. Chemical fills subsequently filled into the mold and the contact lens manufacturing process described in the EXAMPLE 1 above is followed to form the blue colored cosmetic contact lens.
EXAMPLE 3
Following chemicals are mixed to form a clear solution, which will be referred as Chemical V: methacryloxy propyl tris(trimethy siloxysilane) (TRIS) 46.5 parts; methyl methactylate (IvilviA) 8 parts; N,N-dimethylaciylamide (DMAA) 30.5 parts; 1,1,1,3,3,3-hexafluoroisopropyl acrylate 10.5 parts; ethylene glycol dimethacrylate (EGDMA) 4.5 parts; 2,2'-azobis(2,4-dirnethylvaleronilrile) (ADVN) 2.5 parts; and I,3-bis(3-methacryloxy propyl) tetrakis (trimethyl siloxy) disiloxane 1%.
A contact lens was made by canying out the same process as described in the EXAIvIPLE 1 above with Chemical V is optically clear, however, the lens is rigid and hydrophobic, therefore it cannot be used as a soft contact lens.
When mixing 4 parts of Chemical V with one part of Dow Coming 5329.
The contact lens made with the same process as described in the EXAIVIPLE I above, is optically clear and hydrophilic. The contact lens so made has water content of around 18%.
To summarize, the silicone hydrogel contact lens in accordance with the present invention and manufacturing with the method provided herein allows to be used for extended wear. The method of the present invention also provides a low cost process for manufacturing silicone hydrogel contact lens, that enhances market competitiveness.
It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claim, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention.

Claims (14)

  1. I We CLAIM: 1. A method for forming a silicone hydrogel contact lens, comprising the following steps: (I) a mixing step, for mixing silicone lens materials with a filling material to form a new lens material; (2) a lens forming step, in which the new lens material is cured to formalens body; and (3) an extracting step, for removing part or whole filling material to form the silicone hydrogel lens.
  2. 2. The method as claimed in Claim 1, wherein the lens forming step comprises employing a polymerization process to form the lens body.
  3. 3. The method as claimed in Claim I, wherein the filling material comprises water soluble silicone.
  4. 4. The method as claimed in Claim 2, wherein the filling material comprises water soluble silicone.
  5. 5. The method as claimed in Claim 1, wherein the filling material comprises a water soluble silicon-contained surfactant free of polymerizable groups.
  6. 6. The method as claimed in Claim 2, wherein the filling material comprises a water soluble silicon-contained surfactant free of polymerizable groups.
  7. 7. The method as claimed in Claim 3, wherein the filling material comprises a water soluble silicon-contained surfactant free of polymerizable groups.
  8. 8. The method as claimed in Claim 1, wherein the filling material comprises an organic solvent soluble silicone free of polymerizable groups.
  9. 9. The method as claimed in Claim 2, wherein the filling material comprises an organic solvent soluble silicone free of polymerizable groups.
  10. 10. The method as claimed in Claim 3, wherein the filling material comprises an organic solvent soluble silicone free of polymerizable groups.
  11. 11. The method as claimed in Claim 1, wherein the filling material comprises an organic-solvent-soluble silicon-contained suifactant free of polymerizable groups.
  12. 12. The method as claimed in Claim 2, wherein the filling material comprises an organic-solvent-soluble silicon-contained surfactant free of polymerizable gps.
  13. 13. The method as claimed in Claim 3, wherein the filling material comprises an organic-solvent-soluble silicon-contained surfactant fiee of polymerizable groups.
  14. 14. A silicone hydrogel contact lens comprising a lens body containing densely distributed and interconnected pores therein.
GB0725331A 2007-12-31 2007-12-31 A method for the manufacture of silicone hydrogel contact lenses in which filler material is introduced, the lens formed and the filler extracted. Withdrawn GB2456002A (en)

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GB0725331A GB2456002A (en) 2007-12-31 2007-12-31 A method for the manufacture of silicone hydrogel contact lenses in which filler material is introduced, the lens formed and the filler extracted.

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GB2456002A true GB2456002A (en) 2009-07-01

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Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3110405A4 (en) * 2014-02-25 2017-10-18 Oculeve, Inc. Polymer formulations for nasolacrimal stimulation
US10112048B2 (en) 2014-10-22 2018-10-30 Oculeve, Inc. Stimulation devices and methods for treating dry eye
US10155108B2 (en) 2013-04-19 2018-12-18 Oculeve, Inc. Nasal stimulation devices and methods
US10207108B2 (en) 2014-10-22 2019-02-19 Oculeve, Inc. Implantable nasal stimulator systems and methods
US10252048B2 (en) 2016-02-19 2019-04-09 Oculeve, Inc. Nasal stimulation for rhinitis, nasal congestion, and ocular allergies
US10328262B2 (en) 2010-11-16 2019-06-25 The Board Of Trustees Of The Leland Stanford Junior University Stimulation devices and methods
US10426958B2 (en) 2015-12-04 2019-10-01 Oculeve, Inc. Intranasal stimulation for enhanced release of ocular mucins and other tear proteins
US10537469B2 (en) 2013-03-12 2020-01-21 Oculeve, Inc. Implant delivery devices, systems, and methods
US10610695B2 (en) 2014-10-22 2020-04-07 Oculeve, Inc. Implantable device for increasing tear production
US10610095B2 (en) 2016-12-02 2020-04-07 Oculeve, Inc. Apparatus and method for dry eye forecast and treatment recommendation
US10722713B2 (en) 2014-07-25 2020-07-28 Oculeve, Inc. Stimulation patterns for treating dry eye
US10722718B2 (en) 2010-11-16 2020-07-28 The Board Of Trustees Of The Leland Stanford Junior University Systems and methods for treatment of dry eye
US10918864B2 (en) 2016-05-02 2021-02-16 Oculeve, Inc. Intranasal stimulation for treatment of meibomian gland disease and blepharitis

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Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10835748B2 (en) 2010-11-16 2020-11-17 Oculeve, Inc. Stimulation devices and methods
US10722718B2 (en) 2010-11-16 2020-07-28 The Board Of Trustees Of The Leland Stanford Junior University Systems and methods for treatment of dry eye
US11771908B2 (en) 2010-11-16 2023-10-03 The Board Of Trustees Of The Leland Stanford Junior University Systems and methods for treatment of dry eye
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US10967173B2 (en) 2013-04-19 2021-04-06 Oculeve, Inc. Nasal stimulation devices and methods for treating dry eye
US10155108B2 (en) 2013-04-19 2018-12-18 Oculeve, Inc. Nasal stimulation devices and methods
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US10722713B2 (en) 2014-07-25 2020-07-28 Oculeve, Inc. Stimulation patterns for treating dry eye
US10780273B2 (en) 2014-10-22 2020-09-22 Oculeve, Inc. Stimulation devices and methods for treating dry eye
US10610695B2 (en) 2014-10-22 2020-04-07 Oculeve, Inc. Implantable device for increasing tear production
US10207108B2 (en) 2014-10-22 2019-02-19 Oculeve, Inc. Implantable nasal stimulator systems and methods
US10112048B2 (en) 2014-10-22 2018-10-30 Oculeve, Inc. Stimulation devices and methods for treating dry eye
US10426958B2 (en) 2015-12-04 2019-10-01 Oculeve, Inc. Intranasal stimulation for enhanced release of ocular mucins and other tear proteins
US10252048B2 (en) 2016-02-19 2019-04-09 Oculeve, Inc. Nasal stimulation for rhinitis, nasal congestion, and ocular allergies
US10940310B2 (en) 2016-02-19 2021-03-09 Oculeve, Inc. Nasal stimulation for rhinitis, nasal congestion, and ocular allergies
US10918864B2 (en) 2016-05-02 2021-02-16 Oculeve, Inc. Intranasal stimulation for treatment of meibomian gland disease and blepharitis
US10610095B2 (en) 2016-12-02 2020-04-07 Oculeve, Inc. Apparatus and method for dry eye forecast and treatment recommendation

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