US2007216860A1PendingUtilityA1

Molds for producing contact lenses

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Assignee: YIN CHANGHONGPriority: Aug 16, 2002Filed: Sep 15, 2006Published: Sep 20, 2007
Est. expiryAug 16, 2022(expired)· nominal 20-yr term from priority
Inventors:Changhong YinScott F. Ansell
G02B 1/043C08F 232/08B29D 11/00038B29C 33/40C08G 61/08B29D 11/00432B29K 2823/38C08L 39/06C08L 33/26B29D 11/00865C08L 45/00C08L 2205/035C08G 61/02B29D 11/00C08G 61/04
42
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Claims

Abstract

This invention describes molds made from alicyclic co-polymers that are useful in the production of contact lenses and methods for their use.

Claims

exact text as granted — not AI-modified
1 . A mold for making a lens comprising an alicyclic co-polymer wherein said alicyclic co-polymer comprises at least two alicyclic monomers of different chemical structures wherein one curve of the mold comprises said alicyclic co-polymer and the other curve of the mold comprises a Ziegler-Natta catalyst based polypropylene.  
   
   
       2 . The mold of  claim 1  wherein the alicyclic monomers comprise polymerizable cyclobutanes, cyclopentanes, cyclohexanes, cycloheptanes, cycloctanes, biscyclobutanes, biscyclopentanes, biscyclohexanes, biscycloheptanes, biscyclooctanes, or norbornanes.  
   
   
       3 . The mold of  claim 1  wherein the alicyclic monomers are selected from the group consisting of  
     
       
         
         
             
             
         
       
     
     wherein R 1-6  are independently selected from one or more members of the group consisting of hydrogen, C 1-10 alkyl, halogen, hydroxyl, C 1-10 alkoxycarbonyl, C 1-10 alkoxy, cyano, amido, imido, silyl, and substituted C 1-10 alkyl where the substituents are selected from the group consisting of halogen, hydroxyl, C 1-10 alkoxycarbonyl, C 1-10 alkoxy, cyano, amido, imido and silyl.  
   
   
       4 . The mold of  claim 1  wherein the alicyclic monomers are selected from the group consisting of  
     
       
         
         
             
             
         
       
     
     wherein two or more of R 1-6  are taken together to form an unsaturated bond, a carbocyclic ring, a carbocyclic ring containing one or more unsaturated bonds, or an aromatic ring.  
   
   
       5 . The mold of  claim 1  wherein the alicyclic monomers are selected from the group consisting of  
     
       
         
         
             
             
         
       
     
     wherein R 1-6  are independently selected from one or more members of the group consisting of hydrogen, C 1-10 alkyl, halogen, hydroxyl, C 1-10 alkoxycarbonyl, C 1-10 alkoxy, cyano, amido, imido, silyl, and substituted C 1-10 alkyl where the substituents are selected from one or more members of the group consisting of halogen, hydroxyl, C 1-10 alkoxycarbonyl, C 1-10 alkoxy, cyano, amido, imido and silyl.  
   
   
       6 . The mold of  claim 1  wherein the alicyclic monomers are  
     
       
         
         
             
             
         
       
     
     wherein R 1-4  is independently selected from C 1-10 alkyl.  
   
   
       7 . The mold of  claim 1  wherein the alicyclic co-polymer has a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C.  
   
   
       8 . The mold of  claim 1  wherein the mold further comprises an additive.  
   
   
       9 . The mold of  claim 1  wherein the alicyclic co-polymer has a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C.  
   
   
       10 . The mold of  claim 1  wherein the front curve comprises an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C. and the back curve comprises polypropylene having a melt flow of less than about 21 g/10 min.  
   
   
       11 . The mold of  claim 1  wherein the back curve comprises an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C. and the front curve comprises polypropylene having a melt flow of less than about 21 g/10 min.  
   
   
       12 . The mold of  claim 1  wherein the front curve comprises an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C. and the back curve comprises polypropylene having a melt flow of less than about 21 g/10 min and an alicyclic co-polymer having a melt flow of 14, a share rate of MFR=12.0 g and 17.6 g, a specific gravity of 1.01, and a glass transition temperature of 105°.  
   
   
       13 . The mold of  claim 1  wherein the back curve comprises an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C. and the front curve comprises polypropylene having a melt flow of less than about 21 g/10 min and an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C.  
   
   
       14 . The mold of  claim 13  wherein the ratio of alicyclic co-polymer to polypropylene is about 5:95 to about 95:5.  
   
   
       15 . The mold of  claim 13  wherein the ratio of alicyclic co-polymer to polypropylene is about 20:80 to about 80:20.  
   
   
       16 . The mold of  claim 13  wherein the ratio of alicyclic co-polymer to polypropylene is about 40:60 to about 60:40.  
   
   
       17 . A method of making a lens comprising 
 1) dispensing an uncured lens formulation onto a mold surface of a mold of  claim 1 , and    2) curing said lens formulation under suitable conditions.    
   
   
       18 . The method of  claim 17  wherein the mold surface comprises a front curve and a back curve and the method further comprises the step of 
 3) separating the front curve of the lens mold and the back curve of the lens mold where the cured lens removably adheres to the front curve.    
   
   
       19 . The method of  claim 18  wherein the front curve comprises an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C. and the back curve comprises polypropylene having a melt flow of less than about 21 g/10 min.  
   
   
       20 . The method of  claim 18  wherein the front curve comprises an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C. and the back curve comprises polypropylene having a melt flow of less than about 21 g/10 min and an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C.  
   
   
       21 . The method of  claim 20  wherein the ratio of alicyclic co-polymer to polyproylene in the back curve is about 20:80 to about 80:20.  
   
   
       22 . The method of claims  20  wherein the ratio of alicyclic co-polymer to polyproylene in the back curve is about 55:45.  
   
   
       23 . The mold of  claim 1  wherein the lens forming surface comprises a coating effective amount of a high molecular weight coating composition.  
   
   
       24 . A lens produced by the method of claims  17 .  
   
   
       25 . The lens of  claim 24  wherein the uncured lens formulation comprises silicone hydrogel formulations.  
   
   
       26 . The lens of  claim 24  wherein the uncured lens formulation comprises hydrogel formulations.  
   
   
       27 . The lens of  claim 24  wherein the uncured lens formulation comprises the formulations of acquafilcon A, balafilcon A, lotrafilcon A.  
   
   
       28 . The lens of  claim 24  wherein the uncured lens formulations comprise the formulation of etafilcon A, genfilcon A, lenefilcon A, polymacon, acquafilcon A, balafilcon A, galyfilcon A, or senofilcon A, or lotrafilcon A.  
   
   
       29 . The lens of  claim 24  wherein the uncured lens formulation comprises the formulations of acquafilcon A, balafilcon A, lotrafilcon A, galyfilcon A, or senofilcon A.  
   
   
       30 . The lens of  claim 24  wherein the front curve comprises an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C. and the back curve comprises polypropylene having a melt flow of less than about 21 g/10 min.  
   
   
       31 . The lens of  claim 24  wherein the front curve comprises an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C. and the back curve comprises polypropylene having a melt flow of less than about 21 g/10 min and an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C.  
   
   
       32 . The lens of  claim 31  wherein the ratio of alicyclic co-polymer to polyproylene in the back curve is about 20:80 to about 80:20.  
   
   
       33 . The lens of  claim 31  wherein the ratio of alicyclic co-polymer to polyproylene in the back curve is about 55:45.  
   
   
       34 . A method for making a coated lenses comprising 
 (1) coating at least one lens forming surface of a lens mold with a coating effective amount of a high molecular weight coating composition wherein said lens mold comprises an alicyclic co-polymer, polypropylene having a melt flow of less than about 21 g/10 min, and at least one lens forming surface 
 wherein said alicyclic co-polymer comprises at lease two alicyclic monomers of different chemical structures;  
   (2) dispensing an uncured lens formulation onto said at least one lens forming surface; and    (3) curing said lens formulation and said coating composition using a dwell time of less than about 5 minutes and under conditions suitable to form a coated lens.    
   
   
       35 . The method of  claim 34  wherein the high molecular weight coating composition comprises poly(vinyl alcohol), polyethylene oxide, poly(2-hydroxyethyl methacrylate), poly(methyl methacrylate), poly(acrylic acid), poly(methacrylic acid), poly(maleic acid), poly(itaconic acid), poly(acrylamide), poly(methacrylamide), poly(dimethylacrylamide), poly(glycerol methacrylate), polystyrene sulfonic acid, polysulfonate polymers, poly(vinyl pyrrolidone), carboxymethylated polymers, such as carboxymethylcellulose, polysaccharides, glucose amino glycans, polylactic acid, polyglycolic acid, block or random copolymers of the aforementioned, and mixtures thereof.  
   
   
       36 . The method of  claim 34  wherein the high molecular weight coating composition comprises poly(2-hydroxyethyl methacrylate), poly(vinyl pyrrolidone), poly(acrylic acid), poly(methacrylic acid), poly(meth)acrylamide, or poly(acrylamide) and mixtures thereof.  
   
   
       37 . The method of  claim 34  wherein the lens forming surface of the front curve comprises an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C. and the lens forming surface of the back curve comprises polypropylene having a melt flow of less than about 21 g/10 min.  
   
   
       38 . The method of  claim 34  wherein the lens forming surface of the front curve comprises an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105° C. and the lens forming surface of the back curve comprises polypropylene having a melt flow of less than about 21 g/10 min and an alicyclic co-polymer having a MFR of about 11.0 grams/10 minutes to about 18.0 grams/10 minutes, a specific gravity of 1.01 and a glass transition temperature of 105 20  C.  
   
   
       39 . The method of  claim 38  wherein the ratio of alicyclic co-polymer to polyproylene in the back curve is about 20:80 to about 80:20.  
   
   
       40 . The method of claims  38  wherein the ratio of alicyclic co-polymer to polyproylene in the back curve is about 55:45.

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