阅读说明：本技术 超高dk材料 (Ultrahigh DK material ) 是由 詹姆斯·A·小博纳菲尼 于 2018-06-28 设计创作，主要内容包括：一种生产超高Dk材料的方法,包括使以下物质接触并反应：甲基丙烯酸氟代烷基酯；烷基二醇二甲基丙烯酸酯；亲水剂,例如甲基丙烯酸；羟烷基三(三甲基硅烷氧基)硅烷；羟烷基封端的聚二甲基硅氧烷；和苯乙烯基乙基三(三甲基硅烷氧基)硅烷；所述反应在惰性气氛中在至少25磅/平方英寸(PSI)的压力下和在足以产生超高Dk材料的温度下进行一段时间。(A method of producing an ultra-high Dk material comprising contacting and reacting: fluoroalkyl methacrylate; alkyl glycol dimethacrylate; hydrophilic agents such as methacrylic acid; hydroxyalkyl tris (trimethylsiloxy) silane; hydroxyalkyl-terminated polydimethylsiloxanes; and styrylethyltris (trimethylsiloxy) silane; the reaction is conducted in an inert atmosphere at a pressure of at least 25 pounds Per Square Inch (PSI) and at a temperature sufficient to produce an ultra-high Dk material for a period of time.)

1. A method of producing an ultra-high Dk material comprising contacting and reacting:

a) fluoroalkyl methacrylate;

b) alkyl glycol dimethacrylate;

c) a hydrophilic agent;

d) hydroxyalkyl tris (trimethylsiloxy) silane;

e) hydroxyalkyl-terminated polydimethylsiloxanes; and

f) styrylethyltris (trimethylsiloxy) silane,

the reaction is conducted in an inert atmosphere at a pressure of at least 25 pounds Per Square Inch (PSI) and at a temperature sufficient to produce an ultra-high Dk material for a period of time.

2. The method of claim 1, wherein the fluoroalkyl methacrylate is hexafluoroisopropyl methacrylate; the alkyl diol dimethacrylate is neopentyl glycol dimethacrylate; the hydroxyalkyl tri (trimethylsiloxy) silane is 3-methacryloxypropyl tri (trimethylsiloxy) silane; the hydroxyalkyl-terminated polydimethylsiloxane is 4-methacryloxybutyl-terminated polydimethylsiloxane; the hydrophilic agent is methacrylic acid.

3. The method of claim 2, wherein the styrylethyltris (trimethylsiloxy) silane comprises 14 weight percent of the material.

4. The method of claim 1, wherein the styrylethyltris (trimethylsiloxy) silane comprises from 7 to 20 weight percent of the material.

5. The method of claim 4, wherein the styrylethyltris (trimethylsiloxy) silane comprises 14 weight percent of the material.

6. The method of claim 1, wherein the material has a Dk value greater than 175.

7. The method of claim 1, wherein the reaction is conducted under a nitrogen, argon, or helium atmosphere.

8. The method of claim 1, wherein the reaction is performed between 25psi and 1000 psi.

9. The method of claim 1, wherein the reaction is carried out in a vessel in which the ultra-high Dk material is formed into the shape of the vessel.

10. The method of claim 9, wherein the container is selected whereby the high Dk material is formed into a lens, a blank, or a bar.

11. The method of claim 9, wherein the container is comprised of a container material that is permeable to an inert gas comprising an inert atmosphere.

12. The method of claim 11, wherein the container is comprised of polypropylene or polytetrafluoroethylene.

13. The method of claim 1, wherein the reaction is carried out at room temperature.

14. The method of claim 1, wherein the reaction is performed above room temperature.

15. An ultra-high Dk material produced according to the method of claim 1.

Technical Field

The present invention relates to ultra high permeability (Dk) materials and methods thereof; more particularly to ultra-high Dk materials having Dk values greater than 175; and still more particularly to ultra-high dks suitable for use as rigid gas permeable contact lenses.

Background

Initially, rigid contact lenses were constructed from poly (methyl methacrylate) and were impermeable to oxygen. As a result, wearers of such lenses quickly complain of eye fatigue and eye damage due to corneal hypoxia. Thus, contact lens science has evolved to form silicone-based contact lenses, including Rigid Gas Permeable (RGP) contact lenses. Although RGP contact lenses do have some degree of oxygen permeability (Dk values of 30-70, some as high as 140-145), over time, the wearer continues to experience asthenopia and ocular damage. Fatigue and injury remain problems as the cornea becomes hypoxic as wear time increases. Thus, there is a need for a material with ultra-high oxygen permeability (Dk value greater than 175) that is suitable for use as an RGP lens.

Oxygen for aerobic corneal metabolism comes primarily from the atmosphere. Thus, during the wearing of a gas permeable soft or rigid contact lens, the physiological integrity of the cornea is believed to depend primarily on the consumption of oxygen through the lens. Therefore, the prediction of the physiological performance of contact lenses on the eye requires an index that can estimate the passage of oxygen through the lens.

In 1971, Fatt and St.Helen applied Fick's Law to the problem of oxygen passing through contact lenses, thereby introducing the concept of oxygen permeability (Dk/t) into the field. Such bench-top measurements have been widely used as a basis for comparing contact lenses. However, as Fatt indicates, the Dk/t term itself is used as a criterion to measure lens performance as "disappointing". The Dk/t coefficient represents a measure of the "ease" with which oxygen can diffuse through the lens; however, in a given situation, the passage of oxygen through a contact lens also depends on the driving force across the lens, i.e. the partial pressure difference. Oxygen flux (j) is a true index of the amount of oxygen passing through a unit area of the lens in a given time.

Disclosure of Invention

According to one aspect of the invention, a method of producing an ultra-high Dk material comprises contacting and reacting: fluoroalkyl methacrylate; alkyl glycol dimethacrylate; hydrophilic agents such as methacrylic acid; hydroxyalkyl tris (trimethylsiloxy) silane (hydroxyakyl tris (trimethyliloxy) silane); hydroxyalkyl-terminated polydimethylsiloxanes; and styrylethyltris (trimethylsiloxy) silane. The reaction is carried out in an inert atmosphere at a pressure of at least 25 pounds Per Square Inch (PSI) and at a temperature sufficient to produce an ultra-high Dk material for a period of time. For example, the fluoroalkyl methacrylate may be hexafluoroisopropyl methacrylate; the alkyl diol dimethacrylate may be neopentyl glycol dimethacrylate; the hydroxyalkyl tri (trimethylsiloxy) silane may be 3-methacryloxypropyl tri (trimethylsiloxy) silane; the hydroxyalkyl-terminated polydimethylsiloxane may be 4-methacryloxybutyl-terminated polydimethylsiloxane (4-methacryloxybutyl-terminated polydimethylsiloxane). Styrylethyltris (trimethylsiloxy) silane may constitute 14% by weight of the material. The resulting material has a Dk value greater than 175.

According to one aspect of the invention, the reaction is carried out under an atmosphere of nitrogen, argon or helium and is carried out between 25psi and 1000 psi. The reaction can be carried out in a thermostatically controlled oven. The reaction temperature may be room temperature (20 ℃ to 25 ℃) or elevated, for example up to about 50 ℃. The oven may also be programmable to allow variable temperature control during the reaction. The reaction is further carried out in a vessel, wherein the ultra-high Dk material forms the shape of the vessel. In one aspect, the high Dk material is formed into a billet or bar. The container may be constructed of a container material that is permeable to an inert gas, including an inert atmosphere, such as polypropylene or polytetrafluoroethylene.

Detailed Description

Polymerization of suitable monomeric reagents at high pressures can result in polymeric materials having higher oxygen permeability than reactions conducted at ambient pressure. The increase in oxygen permeability is even more pronounced when starting monomers with high oxygen affinity are used. As a result, a material having an ultra-high Dk value can be produced. As used herein, the term "ultra-high Dk" refers to materials having Dk values greater than 175. To this end, the polymerization reaction according to the invention is carried out at room temperature in a thermostatically controlled oven at high pressure (at least 25 psi). "room temperature" may be any value between 20 ℃ and 25 ℃. In accordance with another aspect of the present invention, the polymerization reaction may be conducted at a pressure of greater than 25psi, including up to about 1000psi, and/or at a higher temperature, such as up to about 50 ℃. Higher oxygen permeability can be achieved with increased reaction pressure. In addition, the polymerization reaction should be conducted in an inert atmosphere, such as, but not limited to, a nitrogen, helium, and/or argon atmosphere. Without being bound by any particular theory, it is believed that the ultra-high Dk polymer material is formed as a xerogel or xerogel-like material. It is further believed that the inert gas acts as a solvent and, once the polymer network is formed, is replaced by the surrounding gas, thereby forming a microporous structure. In another aspect of the invention, ultra-high Dk polymeric materials can be produced under supercritical fluid conditions. It is therefore believed that the rigidity of the polymer network obtained by using specific monomers and cross-linking agents prevents collapse of the microporous structure.

In accordance with one aspect of the present invention, Table 1 shows a non-limiting exemplary ultra-high Dk formulation:

TABLE 1

It should be noted that the weight percent (7% to 20%, more specifically 14%) of styrylethyltris (trimethylsiloxy) silane incorporated for polymerization at high pressure (at least 25psi) is critical for the production of ultra-high Dk materials. It is believed that styrylethyltris (trimethylsiloxy) silane contributes to the creation of high free volume structures and has a synergistic effect with 3-methacryloxypropyltris (trimethylsiloxy) silane.

According to another aspect of the invention, a method of producing an ultra-high Dk material comprises contacting and reacting: fluoroalkyl methacrylate; alkyl glycol dimethacrylate; hydrophilic agents such as methacrylic acid; hydroxyalkyl tris (trimethylsiloxy) silane; hydroxyalkyl-terminated polydimethylsiloxanes; and styrylethyltris (trimethylsiloxy) silane. For example, but not limited thereto, the fluoroalkyl methacrylate may be hexafluoroisopropyl methacrylate; the alkyl diol dimethacrylate may be neopentyl glycol dimethacrylate; the hydroxyalkyl tri (trimethylsiloxy) silane may be 3-methacryloxypropyl tri (trimethylsiloxy) silane; the hydroxyalkyl-terminated polydimethylsiloxane may be a 4-methacryloxybutyl-terminated polydimethylsiloxane. The reaction is carried out in an inert atmosphere (e.g., nitrogen, argon, or helium) at a pressure of at least 25psi and at a temperature sufficient to produce an ultra-high Dk material for a period of time. As noted above, the reaction may be carried out at room temperature, e.g., between about 20 ℃ to about 25 ℃, or at elevated temperatures, e.g., up to about 50 ℃, under pressures of about 25psi to about 1000 psi. As a result, ultra-high Dk materials may have Dk values greater than 175, with reactions conducted at higher pressures yielding materials with higher Dk values. Additionally, the ultra-high Dk materials according to the present invention may have a relatively low silicon content, thereby avoiding the surface wetting problems encountered with high silicon gas permeable materials. As a result, the ultra-high Dk materials produced according to the present invention do not require surface treatment, such as plasma treatment.

The polymerization reaction may be carried out in a vessel where the internal dimensions and geometry correspond to the desired dimensions and shape of the ultra-high Dk material. That is, the ultra-high Dk material will polymerize within the container in the shape of the container space. The container may be constructed of a material such as polypropylene or Polytetrafluoroethylene (PTFE) that is permeable to an inert gas including an inert atmosphere. According to one aspect of the invention, the container may be placed in a thermostatically controlled oven set to a specific temperature, for example between 20 ℃ and 50 ℃, or the oven may be programmable so as to allow reactions with variable temperature characteristics.

For example, ultra-high Dk materials produced according to one aspect of the present invention may be used to manufacture Rigid Gas Permeable (RGP) contact lenses. In this non-limiting example, the high Dk material may form a lens, blank or bar having a diameter of about 7mm to 28 mm. The height of the billet may be about 2mm to about 15mm, while the rod may have any desired height. The diameter of the rod or billet may be selected according to its intended use. For example, conventional RGP contact lenses have a diameter of about 7mm to about 12mm (typically 9mm to 10mm), while scleral (scleral) lenses have a diameter of about 14mm to about 24mm (typically 15mm to 20 mm). The blank and rod of ultra-high Dk material may then be shaped by lathing to produce the desired lens, as is known in the art. Alternatively, the lens may be cast directly under the conditions described.

While the invention has been described with reference to a preferred embodiment thereof, it will be understood that various modifications may be made therein without departing from the full spirit and scope of the invention as defined by the following claims.