CA2279452C - Method of preparing foldable high refractive index acrylic ophthalmic device materials - Google Patents
Method of preparing foldable high refractive index acrylic ophthalmic device materials Download PDFInfo
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- CA2279452C CA2279452C CA002279452A CA2279452A CA2279452C CA 2279452 C CA2279452 C CA 2279452C CA 002279452 A CA002279452 A CA 002279452A CA 2279452 A CA2279452 A CA 2279452A CA 2279452 C CA2279452 C CA 2279452C
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
- G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
- G02B1/041—Lenses
- G02B1/043—Contact lenses
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
- A61L27/14—Macromolecular materials
- A61L27/16—Macromolecular materials obtained by reactions only involving carbon-to-carbon unsaturated bonds
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
- A61L27/50—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L2430/00—Materials or treatment for tissue regeneration
- A61L2430/16—Materials or treatment for tissue regeneration for reconstruction of eye parts, e.g. intraocular lens, cornea
Abstract
Foldable, acrylic, high refractive index ophthalmic device materi- als containing a UV absorbing chromophore are cured by exposure to blue light using a benzoylphosphine oxide photoinitiator.
Description
METHOD OF PREPARING FOLDABLE HIGH REFRACTIVE INDEX ACRYLIC
OPHTHALMIC DEVICE MATERIALS
FIELD OF THE INVENTION
This invention relates to photopolymerizable acrylic ophthalmic device materials. In particular, this invention relates to the use of benzoylphosphine oxide initiators in blue-light curing of foldable acrylic ophthalmic device materials.
,o BACKGROUND OF THE INVENTION
The two most common types of polymerization initiators for ophthalmic device materials are thermal initiators and photoinitiators. Typical thermal initiators, including free radical initiators such as peroxides, initiate polymerization ,5 as temperature is increased. In some cases, two or three temperature tiers are involved such that curing involves a schedule of temperature/time combinations.
Thermal initiation generally requires holding the monomer composition at elevated temperatures for lengthy periods of time. Total cure times of twenty-four hours are not unusual. See, for example, U.S. Patent No. 5,290,892.
zo Photoinitiators generally offer the advantage of relatively short cure times and, unlike thermal initiators, can be used at ambient conditions, eliminating the need for high-temperature equipment or special ovens. Photoinitiators are activated by light of one or more specified wavelengths, rather than heat.
25 Photoinitiation of ophthalmic lens materials is known. See, for example, U.S.
Patent No. 5,290,892.
The most common types of photoinitiators known or used for curing ophthalmic lens polymers are probably UV-sensitive photoinitiators. UV-sensitive 3o photoinitiators are, however, generally not suitable for use with lens materials that contain a UV-absorbing chromophore. UV-absorbing chromophores present in an ophthalmic lens composition can interfere with the ability of UV-sensitive photoinitiators to efficiently cure the composition. Today, UV-absorbing chromophores are frequently incorporated in ophthalmic lens materials in order to reduce or block UV light from reaching the retina. Although methods are known for temporarily "blocking" UV absorbing chromophores during processing, thereby preventing interference with a UV-initiator, these methods require that the UV-absorber be "un-blocked" after the composition is cured. The UV chromophore can be "un-blocked" by either chemical or thermal means. "Un-blocking" is generally complicated and can add 4 - 6 hours to processing times, offsetting some or all of the time advantages offered by photoinitiators.
,o In addition to UV-sensitive photoinitiators, visible-light initiators are also known. For example, U.S. Patent No. 5,224,957 discloses photopolymerizable compositions useful in forming an intraocular lens in situ. The compositions are delivered into the natural lens capsule or a thin plastic shell substitute and then ,5 polymerized. The reference compositions contain 90 - 99.99% by weight of at least one polyfunctional acrylic and/or methacrylic acid ester. Suitable acid esters include bisphenol A or bishydroxypolyalkoxy bisphenol A derivatives lengthened with ethylene oxide or propylene oxide.
OPHTHALMIC DEVICE MATERIALS
FIELD OF THE INVENTION
This invention relates to photopolymerizable acrylic ophthalmic device materials. In particular, this invention relates to the use of benzoylphosphine oxide initiators in blue-light curing of foldable acrylic ophthalmic device materials.
,o BACKGROUND OF THE INVENTION
The two most common types of polymerization initiators for ophthalmic device materials are thermal initiators and photoinitiators. Typical thermal initiators, including free radical initiators such as peroxides, initiate polymerization ,5 as temperature is increased. In some cases, two or three temperature tiers are involved such that curing involves a schedule of temperature/time combinations.
Thermal initiation generally requires holding the monomer composition at elevated temperatures for lengthy periods of time. Total cure times of twenty-four hours are not unusual. See, for example, U.S. Patent No. 5,290,892.
zo Photoinitiators generally offer the advantage of relatively short cure times and, unlike thermal initiators, can be used at ambient conditions, eliminating the need for high-temperature equipment or special ovens. Photoinitiators are activated by light of one or more specified wavelengths, rather than heat.
25 Photoinitiation of ophthalmic lens materials is known. See, for example, U.S.
Patent No. 5,290,892.
The most common types of photoinitiators known or used for curing ophthalmic lens polymers are probably UV-sensitive photoinitiators. UV-sensitive 3o photoinitiators are, however, generally not suitable for use with lens materials that contain a UV-absorbing chromophore. UV-absorbing chromophores present in an ophthalmic lens composition can interfere with the ability of UV-sensitive photoinitiators to efficiently cure the composition. Today, UV-absorbing chromophores are frequently incorporated in ophthalmic lens materials in order to reduce or block UV light from reaching the retina. Although methods are known for temporarily "blocking" UV absorbing chromophores during processing, thereby preventing interference with a UV-initiator, these methods require that the UV-absorber be "un-blocked" after the composition is cured. The UV chromophore can be "un-blocked" by either chemical or thermal means. "Un-blocking" is generally complicated and can add 4 - 6 hours to processing times, offsetting some or all of the time advantages offered by photoinitiators.
,o In addition to UV-sensitive photoinitiators, visible-light initiators are also known. For example, U.S. Patent No. 5,224,957 discloses photopolymerizable compositions useful in forming an intraocular lens in situ. The compositions are delivered into the natural lens capsule or a thin plastic shell substitute and then ,5 polymerized. The reference compositions contain 90 - 99.99% by weight of at least one polyfunctional acrylic and/or methacrylic acid ester. Suitable acid esters include bisphenol A or bishydroxypolyalkoxy bisphenol A derivatives lengthened with ethylene oxide or propylene oxide.
2° The compositions of the '957 patent are cured using photoinitiators which absorb light in the range 400 - 500 nm. Suitable initiators include alpha-diketones, in particular camphorquinone, benzil and phenanthrene quinone, and mono and bisacylphosphine oxides. According to the '957 patent, particularly preferred initiators are "for example 2,4,6-trimethylbenzoyldiphenylophosphine Z5 oxide and bis-(2,6-dichlorobenzoyl)-4-n-propylphenylphosphine oxide or bis-(2,6 dichlorobenzoyl)-4-n-butylphenylphosphine oxide" (see Col. 3, lines 12-16}.
International Patent Application Publication No. WO 96/28762 also discloses photocurable compositions comprising acrylic components. The compositions 3o contain specified amounts of di(meth)acrylates, poly(meth}acrylates, urethane(meth)acrylates, and oligomeric di(meth)acrylates based on bisphenol A
or bisphenol F. The photoinitiator may be "any photoinitiator which forms free radicals when irradiated suitably." Suitable classes include benzoin ethers;
acetophenones;
benzil; anthraquinones; benzoylphosphine oxides (e.g., 2,4,6-trimethylbenzoyldiphenylphosphine oxide); benzophenones. Photoinitiators particularly suitable for use with argon ion lasers include 2,4,6-trimethylbenzoyldiphenylphosphine oxide.
SUMMARY OF THE INVENTION
The present invention relates to methods for preparing foldable acrylic, high ,o refractive index ophthalmic device materials that contain a UV-absorbing chromophore and a benzoylphosphine oxide photoinitiator. The methods comprise activating the benzoylphosphine oxide photoinitiator with a blue-light source.
Among other factors, the present invention is based on the finding that ,5 foldable, acrylic, high-refractive index ophthalmic device materials that contain a UV absorber are effectively cured using a blue light source and the benzoylphosphine oxide initiator, 2,4,6-trimethyl-benzoyldiphenylophosphine oxide. In contrast, when camphorquinone, which has a greater absorbency in the blue-light region than 2,4,6-trimethyl-benzoyldiphenylophosphine oxide, is used in 2o place of the benzoylphosphine oxide initiator, the same ophthalmic device materials are not efficiently cured.
BRIEF DESCRIPTION OF THE DRAWINGS
25 Figure 1 shows a sample UV-visible spectrum of the benzoylphosphine oxide initiator 2-4-6- trimethylbenzoyldiphenylophosphine oxide in a 2-phenylethyl acrylate solvent.
Figure 2 shows a sample UV-visible spectrum of the alpha-diketone 3o initiator camphorquinone in a 2-phenylethyl acrylate solvent.
Figure 3 shows a sample UV-visible spectrum of the UV chromophore 2-(3'-methaliyl-2'fiydroxy 5'-methylphenyl)benzotriazole in a 2-phenylethyl acryiate solvent.
DETAILED DESCRIPTION OF THE INVENTION AND PREFERRED
s~ EMgODIM~NTS
As used herein, "high refractive index" means a refractive index of about 1.50 or greater when measured at room temperature using a sodium lamp.
,o According to the present invention, foldable, acrylic, high refractive index ophthalmic device materials comprising one or more monomers having the stntcture of Formula I below are prepared using a blue-light source and a benzoyl-phosphine oxide initiator. First, an ophthalmic device material mixture comprising a benzoylphosphine oxide initiator a UV absorber and one or more ,s compounds of Formula I below is prepared.
X
CH2=C-C00-(CH~)m Y-Ar (I) wherein: X is H or CH3;
m is an integer from 0-10;
Y is a single bond,0, S, or NR wherein R is H, CH3, C~HZ"+~, wherein n is an integer from 1-10, iso OC3H~, CgHS, or CHZCeH5;
Ar is any anxnafic ring which can be unsubstitubed or substituted with H, CHs, Cztis, n-C3H~, iso-C3H,, OCH3, CaH", CI, Br, CsHs, or CH2CBHs.
After the mixture is prepared, it is exposed to a blue-light source for a time sufficient to cun: the device material.
Monomers of Fomlula I are knoHm and include, but are not limited to: 2-phenoxyethyl acrytate, 2-phenylethytthio acxylate, 2-phenylethylamino acrylate, phenyl acxylate, benzyl acrylate, 2-phenylethyl acrylate, 3-phenyipropyl acrylate, 4-I
I I I I i phenylbutyl aaylate, 4-methylphenyl acrylate, 4-methylbenzyl acxylate, 2-2-methylphenylethyl acrylate, 2-3-methylphenylethyl acrytate, 2-4-rr~ethylphenylethyl acryiate, and the like, including their corresponding methacrylates. These aarylic/methaaylic monomers and others are disclosed in U.S. Patent No.
s ~ 5,290,892.
Preferred monomers of Formula (I) are those where X is H; m is 2-4; Y is nothing or O; and Ar is phenyl. Most preferred are 2-phenylethyl acrylate, 2-phenoxyethyl acxylate, 3-phenylpropyl adylate, 3-phenoxypropyl acrylate, 4-,° phenylbufyl acrylate, and 4-phenoxybutyl acrytate.
The exact amount of monomer of Formula I present in the foldable, acrylic, high refracfrve index ophthalmic device materials of the pn..sent invention will vary depending upon the identity of the monomers) of Formula I, the identify of any ,s other device-forming monomers) present in the materials, and the desired rr~chanical properties. For example, foldable intraocular lenses are preferably made from polymers having a glass transition temperature no greater than normal room temperature, e.g., about 20 - 25 °C, in order that the lenses can be rolled or folded conveniently at room temperature. Glass transition temperature is determined at room temperature using a differential scanning calorimeter at a heating rate of 10°C/min. Addifronally, materials exhibiting an elongation of at least 150°r6 when measured at room temperature using an Instron tensile tester.at a cross-head speed of 50 crnlmin) are prefen~d for use in foldable intraocular-lenses because such lenses must exhibit sufficient strength to allow them to be ~s folded without fracturing. For foldable intraocular lens applications, polymers having an elongation of at least 200°~ an: more preferred.
Materials containing less than about 50°~ (wlw) of monomers containing an aromatic moiety are generally not high refractive index materials. Thus, in ~o general, the foldable, acrylic, high refractive index ophthalmic device materials of the present invention will contain at least 50% (w/w) of monomers) of Formula 1.
Preferably, the device materials will contain one or more monomers of Formula I
in an amount totaling 70% (w/w) or more, and most preferably, 80% (wlw) or more.
Device-forming monomers other than those of Formula 1 optionally may be s included in the compositions of the present invention. Many such ophthalmic device-forming monomers are known. Any known device-forming monomer may be used if it is compatible with the monomers) of Formula I present in the composition and does not interfere with the ability of the benzoylphosphine oxide photoinitiator to cure the composition when exposed to blue light. Suitable ,° device-forming monomers other than those of Formula I include, but are not limited to: C, - Ce alkylacrylates, C, - Ce cycloalkylacrylates, N-alkylacrylamides (where alkyl = C, - C,), phenoxyalkylacrylates (where alkyl = C, - C$), giycerylacrylate, polyethyleneoxide mono- and diacrylates, 2-hydroxyethyfacrylates, and their corresponding methacrylates. Suitable device-,s forming monomers other than those of Formula 1 also include N-vinylpyrrolidone.
See U.S. Patent No. 5;331,073, for examples of device-forming materials containing one monomers of Formula 1 in combination with such suitable device-forming monomers.
As in the case of the monomers) of Formula 1, the amount of any other device-forming monomers present in the ophthalmic device materials of the invention will vary depending upon the identity of the monomers) of Formula l, the identity of the optional device-forming monomer(s), and . the mechanical properties desired for the polymerized ophthalmic material. In general, for foldable intraocular lens applications, the ophthalmic device material& of the present invention may contain about 45% (w/w) or less, and preferably about 30%
(wlw) or less, of device-forming monomers other than those of Formula I.
Ultraviolet absorbing chromophores are also included in the ophthalmic device materials of the present invention. Such chromophores prevent or inhibit UV light from damaging the eye. In the case of intraocular lenses, UV
absorbers s allow the light absorbance of an intraocular lens to approximate that of the eye's natural lens. The ultraviolet absorbing chromophore ih the device material of the present invention can be any compound which absorbs light having a wavelength shorter than about 400 nm, but does not absorb any substantial amount of visible light, and which is compatible with the device-forming monomers) present in the material . The ultraviolet absorbing compound is incorporated into the monomer mixture and is entrapped in the polymer matrix when the monomer mixture is polymerized. Suitable ultraviolet absorbing compounds include substituted benzophenones, such as 2-hydroxybenzophenone, and 2-(2-hydroxyphenyl)-,o benzotriazoles. It is preferred to use an ultraviolet absorbing compound that is copolymerizable with the device-forming monomers described above so that it will be covalently bound to the polymer matrix. In this way, possible teaching of the ultraviolet absorbing compound out of the device and into the interior of the eye is minimized. Suitable copolymerizable ultraviolet absorbing compounds are the ,5 substituted 2-hydroxybenzophenones disclosed in U.S. Patent No. 4,304,895 and the 2-hydroxy-5-acryloxyphenyl-2H-benzotriazoles disclosed in U.S. Patent No.
4,528,311. The most preferred ultraviolet absorbing compound is 2-(3'-methallyl-2'-hydroxy-5'-methyl phenyl) benzotriazole.
2o In addition to the device-forming monomers) and the UV-absorber, the device materials of the present invention contain a benzoylphosphine oxide as a photoinitiator. Benzoylphosphine oxide initiators are known and are commercially available. Examples of benzoylphosphine initiators include 2,4,6-trimethyl-benzoyldiphenylophosphine oxide; bis-(2,6-dichlorobenzoyl)-4-N-propylphenyl-Z5 phosphine oxide; and bis-(2,6-dichlorobenzoyl)-4-N-butylphenylphosphine oxide.
Most preferred is 2,4,6-trimethyl-benzoyldiphenylophosphine oxide, commercially available as Lucirin~ TPO from BASF Corporation (Charlotte, North Carolina).
The amount of benzoylphosphine oxide initiator in the device materials of the present invention will depend upon the identity of the other ingredients in the materials, the light flux, and other processing conditions such as the desired curing time and the presence of inhibitors such as oxygen. In general, however, *rB
the amount of benzoylphosphine oxide initiator will be about 3% or less, preferably about 2% or less, and most preferably about 1 %.
Although not essential, the ophthalmic device materials of the present invention may optionally contain one or more copolymerizable cross-linking monomers. The use of cross-linking monomers is preferred. If desired, suitable cross-linking monomers include almost any terminally ethylenically unsaturated compound having more than one unsaturated group. Suitable cross-linking agents include, for example: ethyleneglycol dimethacrylate; diethylene glycol ,° dimethacrylate; ethyleneglycol diacrylate; allyl methacrylates;
allyl acrylates; 1,3-propanediol dimethacrylate; 1,6-hexanediol dimethacrylate; 1,4-butanediol dimethacrylate; polyethyleneoxide mono- and diacrylates; and the like. A
preferred cross-linking agent is 1,4-butanediol diacrylate (BDDA). A preferred cross-linking agent is 1,4-butanediol diacrylate (BDDA). The amount of cross-linking agent ,5 generally will be less than about 10% (wlw) or less, preferably about 5%
(w/w) or less.
Blue-light absorbing compounds are also optionally included in the device materials of the present invention. The blue-light absorbing compound, e.g.
yellow 2o dyes, should only be used in an amount at which they do not substantially interfere with the blue light source's ability to activate the benzoylphosphine oxide initiator.
The presence of a blue-light absorber may necessitate an increased amount of benzoylphosphine oxide initiator. Preferably, blue-light absorbers are copolymerizable with the device-forming monomers. Suitable polymerizable blue-25 light blocking chromophores include those disclosed in U.S. Patent No.
International Patent Application Publication No. WO 96/28762 also discloses photocurable compositions comprising acrylic components. The compositions 3o contain specified amounts of di(meth)acrylates, poly(meth}acrylates, urethane(meth)acrylates, and oligomeric di(meth)acrylates based on bisphenol A
or bisphenol F. The photoinitiator may be "any photoinitiator which forms free radicals when irradiated suitably." Suitable classes include benzoin ethers;
acetophenones;
benzil; anthraquinones; benzoylphosphine oxides (e.g., 2,4,6-trimethylbenzoyldiphenylphosphine oxide); benzophenones. Photoinitiators particularly suitable for use with argon ion lasers include 2,4,6-trimethylbenzoyldiphenylphosphine oxide.
SUMMARY OF THE INVENTION
The present invention relates to methods for preparing foldable acrylic, high ,o refractive index ophthalmic device materials that contain a UV-absorbing chromophore and a benzoylphosphine oxide photoinitiator. The methods comprise activating the benzoylphosphine oxide photoinitiator with a blue-light source.
Among other factors, the present invention is based on the finding that ,5 foldable, acrylic, high-refractive index ophthalmic device materials that contain a UV absorber are effectively cured using a blue light source and the benzoylphosphine oxide initiator, 2,4,6-trimethyl-benzoyldiphenylophosphine oxide. In contrast, when camphorquinone, which has a greater absorbency in the blue-light region than 2,4,6-trimethyl-benzoyldiphenylophosphine oxide, is used in 2o place of the benzoylphosphine oxide initiator, the same ophthalmic device materials are not efficiently cured.
BRIEF DESCRIPTION OF THE DRAWINGS
25 Figure 1 shows a sample UV-visible spectrum of the benzoylphosphine oxide initiator 2-4-6- trimethylbenzoyldiphenylophosphine oxide in a 2-phenylethyl acrylate solvent.
Figure 2 shows a sample UV-visible spectrum of the alpha-diketone 3o initiator camphorquinone in a 2-phenylethyl acrylate solvent.
Figure 3 shows a sample UV-visible spectrum of the UV chromophore 2-(3'-methaliyl-2'fiydroxy 5'-methylphenyl)benzotriazole in a 2-phenylethyl acryiate solvent.
DETAILED DESCRIPTION OF THE INVENTION AND PREFERRED
s~ EMgODIM~NTS
As used herein, "high refractive index" means a refractive index of about 1.50 or greater when measured at room temperature using a sodium lamp.
,o According to the present invention, foldable, acrylic, high refractive index ophthalmic device materials comprising one or more monomers having the stntcture of Formula I below are prepared using a blue-light source and a benzoyl-phosphine oxide initiator. First, an ophthalmic device material mixture comprising a benzoylphosphine oxide initiator a UV absorber and one or more ,s compounds of Formula I below is prepared.
X
CH2=C-C00-(CH~)m Y-Ar (I) wherein: X is H or CH3;
m is an integer from 0-10;
Y is a single bond,0, S, or NR wherein R is H, CH3, C~HZ"+~, wherein n is an integer from 1-10, iso OC3H~, CgHS, or CHZCeH5;
Ar is any anxnafic ring which can be unsubstitubed or substituted with H, CHs, Cztis, n-C3H~, iso-C3H,, OCH3, CaH", CI, Br, CsHs, or CH2CBHs.
After the mixture is prepared, it is exposed to a blue-light source for a time sufficient to cun: the device material.
Monomers of Fomlula I are knoHm and include, but are not limited to: 2-phenoxyethyl acrytate, 2-phenylethytthio acxylate, 2-phenylethylamino acrylate, phenyl acxylate, benzyl acrylate, 2-phenylethyl acrylate, 3-phenyipropyl acrylate, 4-I
I I I I i phenylbutyl aaylate, 4-methylphenyl acrylate, 4-methylbenzyl acxylate, 2-2-methylphenylethyl acrylate, 2-3-methylphenylethyl acrytate, 2-4-rr~ethylphenylethyl acryiate, and the like, including their corresponding methacrylates. These aarylic/methaaylic monomers and others are disclosed in U.S. Patent No.
s ~ 5,290,892.
Preferred monomers of Formula (I) are those where X is H; m is 2-4; Y is nothing or O; and Ar is phenyl. Most preferred are 2-phenylethyl acrylate, 2-phenoxyethyl acxylate, 3-phenylpropyl adylate, 3-phenoxypropyl acrylate, 4-,° phenylbufyl acrylate, and 4-phenoxybutyl acrytate.
The exact amount of monomer of Formula I present in the foldable, acrylic, high refracfrve index ophthalmic device materials of the pn..sent invention will vary depending upon the identity of the monomers) of Formula I, the identify of any ,s other device-forming monomers) present in the materials, and the desired rr~chanical properties. For example, foldable intraocular lenses are preferably made from polymers having a glass transition temperature no greater than normal room temperature, e.g., about 20 - 25 °C, in order that the lenses can be rolled or folded conveniently at room temperature. Glass transition temperature is determined at room temperature using a differential scanning calorimeter at a heating rate of 10°C/min. Addifronally, materials exhibiting an elongation of at least 150°r6 when measured at room temperature using an Instron tensile tester.at a cross-head speed of 50 crnlmin) are prefen~d for use in foldable intraocular-lenses because such lenses must exhibit sufficient strength to allow them to be ~s folded without fracturing. For foldable intraocular lens applications, polymers having an elongation of at least 200°~ an: more preferred.
Materials containing less than about 50°~ (wlw) of monomers containing an aromatic moiety are generally not high refractive index materials. Thus, in ~o general, the foldable, acrylic, high refractive index ophthalmic device materials of the present invention will contain at least 50% (w/w) of monomers) of Formula 1.
Preferably, the device materials will contain one or more monomers of Formula I
in an amount totaling 70% (w/w) or more, and most preferably, 80% (wlw) or more.
Device-forming monomers other than those of Formula 1 optionally may be s included in the compositions of the present invention. Many such ophthalmic device-forming monomers are known. Any known device-forming monomer may be used if it is compatible with the monomers) of Formula I present in the composition and does not interfere with the ability of the benzoylphosphine oxide photoinitiator to cure the composition when exposed to blue light. Suitable ,° device-forming monomers other than those of Formula I include, but are not limited to: C, - Ce alkylacrylates, C, - Ce cycloalkylacrylates, N-alkylacrylamides (where alkyl = C, - C,), phenoxyalkylacrylates (where alkyl = C, - C$), giycerylacrylate, polyethyleneoxide mono- and diacrylates, 2-hydroxyethyfacrylates, and their corresponding methacrylates. Suitable device-,s forming monomers other than those of Formula 1 also include N-vinylpyrrolidone.
See U.S. Patent No. 5;331,073, for examples of device-forming materials containing one monomers of Formula 1 in combination with such suitable device-forming monomers.
As in the case of the monomers) of Formula 1, the amount of any other device-forming monomers present in the ophthalmic device materials of the invention will vary depending upon the identity of the monomers) of Formula l, the identity of the optional device-forming monomer(s), and . the mechanical properties desired for the polymerized ophthalmic material. In general, for foldable intraocular lens applications, the ophthalmic device material& of the present invention may contain about 45% (w/w) or less, and preferably about 30%
(wlw) or less, of device-forming monomers other than those of Formula I.
Ultraviolet absorbing chromophores are also included in the ophthalmic device materials of the present invention. Such chromophores prevent or inhibit UV light from damaging the eye. In the case of intraocular lenses, UV
absorbers s allow the light absorbance of an intraocular lens to approximate that of the eye's natural lens. The ultraviolet absorbing chromophore ih the device material of the present invention can be any compound which absorbs light having a wavelength shorter than about 400 nm, but does not absorb any substantial amount of visible light, and which is compatible with the device-forming monomers) present in the material . The ultraviolet absorbing compound is incorporated into the monomer mixture and is entrapped in the polymer matrix when the monomer mixture is polymerized. Suitable ultraviolet absorbing compounds include substituted benzophenones, such as 2-hydroxybenzophenone, and 2-(2-hydroxyphenyl)-,o benzotriazoles. It is preferred to use an ultraviolet absorbing compound that is copolymerizable with the device-forming monomers described above so that it will be covalently bound to the polymer matrix. In this way, possible teaching of the ultraviolet absorbing compound out of the device and into the interior of the eye is minimized. Suitable copolymerizable ultraviolet absorbing compounds are the ,5 substituted 2-hydroxybenzophenones disclosed in U.S. Patent No. 4,304,895 and the 2-hydroxy-5-acryloxyphenyl-2H-benzotriazoles disclosed in U.S. Patent No.
4,528,311. The most preferred ultraviolet absorbing compound is 2-(3'-methallyl-2'-hydroxy-5'-methyl phenyl) benzotriazole.
2o In addition to the device-forming monomers) and the UV-absorber, the device materials of the present invention contain a benzoylphosphine oxide as a photoinitiator. Benzoylphosphine oxide initiators are known and are commercially available. Examples of benzoylphosphine initiators include 2,4,6-trimethyl-benzoyldiphenylophosphine oxide; bis-(2,6-dichlorobenzoyl)-4-N-propylphenyl-Z5 phosphine oxide; and bis-(2,6-dichlorobenzoyl)-4-N-butylphenylphosphine oxide.
Most preferred is 2,4,6-trimethyl-benzoyldiphenylophosphine oxide, commercially available as Lucirin~ TPO from BASF Corporation (Charlotte, North Carolina).
The amount of benzoylphosphine oxide initiator in the device materials of the present invention will depend upon the identity of the other ingredients in the materials, the light flux, and other processing conditions such as the desired curing time and the presence of inhibitors such as oxygen. In general, however, *rB
the amount of benzoylphosphine oxide initiator will be about 3% or less, preferably about 2% or less, and most preferably about 1 %.
Although not essential, the ophthalmic device materials of the present invention may optionally contain one or more copolymerizable cross-linking monomers. The use of cross-linking monomers is preferred. If desired, suitable cross-linking monomers include almost any terminally ethylenically unsaturated compound having more than one unsaturated group. Suitable cross-linking agents include, for example: ethyleneglycol dimethacrylate; diethylene glycol ,° dimethacrylate; ethyleneglycol diacrylate; allyl methacrylates;
allyl acrylates; 1,3-propanediol dimethacrylate; 1,6-hexanediol dimethacrylate; 1,4-butanediol dimethacrylate; polyethyleneoxide mono- and diacrylates; and the like. A
preferred cross-linking agent is 1,4-butanediol diacrylate (BDDA). A preferred cross-linking agent is 1,4-butanediol diacrylate (BDDA). The amount of cross-linking agent ,5 generally will be less than about 10% (wlw) or less, preferably about 5%
(w/w) or less.
Blue-light absorbing compounds are also optionally included in the device materials of the present invention. The blue-light absorbing compound, e.g.
yellow 2o dyes, should only be used in an amount at which they do not substantially interfere with the blue light source's ability to activate the benzoylphosphine oxide initiator.
The presence of a blue-light absorber may necessitate an increased amount of benzoylphosphine oxide initiator. Preferably, blue-light absorbers are copolymerizable with the device-forming monomers. Suitable polymerizable blue-25 light blocking chromophores include those disclosed in U.S. Patent No.
5,470,932.
The device materials of this invention are prepared by forming a mixture of the device-forming monomer{s) (monomer(s) of Formula I and any optional device-forming monomer), the UV-absorbing chromophore, and the benzoylphosphine 3° oxide initiator, along with any other suitable ingredients, in the desired proportions.
The mixture can then be introduced into a mold of suitable shape to form an ophthalmic device, and the polymerization carried out by exposure to blue-light.
s 'I
The device materials of the present invention are preferably cured in vitro.
Blue-light sources are commeraally available and include: the Palatray CU
blue-light unit (available from Heraeus Kufzer, Inc., Irvine, California), the Fusion s F450*blue light system (available from TEAMCO, Richardson, Texas) and the GE
24" blue fluorescent lamp (available from General Electric Company, U.S.). A
preferred blue-light source is the Palatray CU blue-light unit. Suitable blue-Ight sounds emit light in the 400 - 500 nm range sufficient to activate benzoylphosphine oxide initiators. Suitable blue-light sources include sunlight and standard white ,o fluorescent light bulbs, for example, though these sources would require longer exposure times to achieve complete cures than sources which emit light in the - 500 nm range at higher intensities.
The intensity of the blue light from the blue-light source is preferably from ,s about 1 to about 40 mWlcmZ. An intensity in the blue-light region of from about 10 to about 15 mWlcm2 is more preferred. If the intensity of blue-light is too great, in addition to shrinkage problems created during curing, the device material may turn yellow or otherwise become discolored.
o The length of time necessary for the device materials of the present invention to be exposed to a blue light source in order to be cured will depend upon a variety of factors, including the reactivity of the device material ingredients, the size and mass of the sample to be cured, the initiator concentration and the intensity of the blue-light source. In general, for individually cast devices, exposure times will range from about 5 minutes to about 4 hours, preferably from about minutes to about 2 hours. Attempting to cure.the materials too quickly may result in compnxnised optical properties; too rapid cross-linking may cause shrinkage-related stresses within the cured polymer that distort the surface of the device as they are relieved.
For exposure times of about an hour or less, it is preferred that the molds containing the device materials not be opened immediately after being exposed to *Trade-mark g blue-light. Leaving the molds unopened for approximately one hour allows residual curing reactions to be completed.
The ophthalmic device materials prepared according to the present invention may be used to make almost any type of ophthalmic lens, including contact lenses, intracorneal lenses and intraocular lenses. Ophthalmic lenses constructed of the disclosed materials can be of any design, but are preferably intraocular lenses (IOLs) capable of being rolled or folded and inserted through a relatively small incision. For example, the IOLs can be of what is known as a one piece or ,0 multipiece design. Typically, an IOL comprises an optic and at least one haptic.
The optic is that portion which serves as the lens and the haptics are attached to the optic and are like arms that hold the optic in its proper place in the eye. The optic and haptic(s) can be of the same or different material. Haptics may be attached to the optic using conventional techniques. In a single piece lens, the ,5 optic and the haptics are formed out of one piece of material. Depending on the material, the haptics are then cut, or lathed, out of the material to produce the IOL.
In addition to ophthalmic lenses, the materials prepared according to the methods of the present invention may also be used to make other ophthalmic devices including, but not limited to, keratoprostheses and corneal inlays or rings.
Molding and drilling operations are easily carried out if the device, e.g., an IOL optic, is molded between two polypropylene mold halves. The mold containing the cured device material is then placed on a lathe and the desired shape is lathe cut. The mold may then be easily mounted to carry out any drilling operations prior Z5 to removing the mold halves. Both the lathing and drilling operations may be facilitated by cooling the mold/device in a freezer to less than 10°C
and preferably less than 0°C prior to each of these operations. If premature release of one or both mold halves occurs, it may be necessary to use clamps or alternative mold materials or to treat the surface of the mold halves.
The invention will be further illustrated by the following examples which are intended to be illustrative, but not limiting.
*rB
EXAMPLES
The following mixtures shown below in Table 1 were prepared and transferred into molds for curing:
Table 1 PEMA - . 1pp30 POEA - 89.6 89.587.8 87.7 - 10 99.655 10 97.85 -EGDMA 0.350.35 0.350.350.350.35 BDDA 1 1 3.23.2 OMTP 1.81.8 1.8 1.8 1.8 PEA = 2-phenylethylacrylate s PEMA = 2-phenylethylmethacrylate MMA = methyl methacrylate HEMA = 2-hydroxyethylmethacrylate POEA = 2-phenoxyethyl acrylate (passed through basic alumina) HA = N-hexyl acrylate (passed through basic alumina) ,o NVP = N-vinyl pyrrolidone (passed through acidic alumina) EGDMA = ethyleneglycoldimethacrylate BDDA = 1,4-butanediol diacrylate OMTP = o-Methyl. Tinuvin P (2-(3'-methallyl-2'-hydroxy-5'-methyl phenyl)-benzotriazole) ,s "All values are expressed as parts by weight.
The compositions of Examples 1 - 14 were then cured according to each of three cure profiles as indicated below in Table 2: a thermal cure system using the thermal initiator Perkadox 16 and a curing temperature of 70 °C for 1 hour; and two 2o photoinitiators, camphorquinone and Lucirin~ TPO, respectively, using a blue-light source with exposure times of 15, 30 and 60 minutes. After completing the cure profile, all molds were left uriopened for approximately 1 hour. After opening the molds, physical appearance was recorded. "Liquid" indicates that the sample did not appear to cure to any significant extent. "Gel-slime" indicates that the sample 25 cured to some extent, but still appeared to be primarily a liquid. "Gel"
indicates that the sample cured to a loose solid. "Solidn indicates that the sample appeared to cure thoroughly or completely.
After the physical appearance of each sample was recorded, the samples rated "solid" were extracted in acetone. These samples were weighed ("initial weight"), placed into hot (near boiling) acetone for two hours, and then dried for two hours in an air-circulating oven. After drying, the samples were weighed again ("final weight"). The percent extractables were calculated as follows:
(initial weight -final weight)/(initial weight) x 100. For samples rated "liquid," no weight measurements were taken; % extractables for these samples was estimated to be 100%. For samples rated "Gel-slime" or "Gel" no weight measurements were taken;
,° % extractables for these samples was estimated to be > 95%. The physical appearance and the level of extractables for each of the samples of Table 1 are shown below in Table 2.
Cure Profile1 hrI70C 15 15 I
oven I 30 /
30 60 min l 14 mW/cm2 60 blue min li ht mW/cm2 blue light Initiator Perkadox-16dl-Camphorquinone Lucirin~
(concentration)(1 %) (0.5%) TPO
(0.5%) Example Cure esults # R
1 solid gel-slime/ solid/
el-slime! solid/
solid solid 2 liquid liquidlli liquid/li uidlliquid uidlli uid 3 liquid eU solid/
eU solid/
e! solid 4 liquid IiquidAiquidlliquid liquid/liquidlliquid solid liquid/liquidlliquid liquidlliquid/liquid 6 solid liquidlliquid/ solid!
e! solid/
solid 7 solid solid/ solid/
solid/ solid) solid solid 8 solid gel/gel/solid solid/
solid/
solid 9 solid solid/ solid!
solid/ solid/
solid solid solid geI/geU gel/ eU
e! e!
11 solid solid/ solid!
solid! solid!
solid solid 12 solid solid/ solid!
solid/ solid) solid solid 13 solid liquid/liquidlliquid gellgeUgel 14 solid solid/ solid!
solid/ solid/
solid solid ACETONE "
EXTRACTABLES
EXAMPLE
#
1 <1 > > 95 3.0 <1 <1 <1 5 8.0 100 100 100 100 100 100 6 0.9 100 100 ND 19.9 10.7 12.1 7 8.5 ND ND 18.8 3.2 1.9 1.9 8 6.7 >95 >95 8.8 3.9 2.2 2.1 9 8.6 6.2 6.6 6.4 4.4 5.5 3.8 10 9.2 >95 >95 >95 >95 >95 >95 11 7.5 6.8 5.5 5.3 4.4 3.9 4.1 12 20.4 48.3 22.2 11.8 6.1 5.9 5.9 13 13.2 100 100 100 >95 >95 >95 14 21.5 46.1 35.1 33.4 7.3 6.8 7.1 ~rvu = not aetermmea The results of Table 2 are discussed with reference to the type of device-forming monomers) present in the samples:
a) Aryl (meth)acrylate based polymers (Examples 6 - 9, 11, 12, and 14) ,o When the samples lacked an UV-absorber (Examples 9 and 11 ), they cured similarly in the presence of either blue-light initiator, camphorquinone ("CQ") or Lucirin~ TPO ("TPO"), with the TPO-cured samples showing somewhat lower extractables. In contrast, when the samples contained an UV-absorber (Examples 6 - 8, 12 and 14), the CQ initiator gave much poorer results: in all such cases, the extractables were significantly higher for the samples cured with CQ
than with TPO.
b~ Alkyl (m~th)acrylate based polymers (Examples 5, 10 and 13) Although the samples of Examples 5, 10 and 13 all cured to some extent when the thermal initiator was used, all of these samples cured very poorly when either ,o CQ or TPO was used as an initiator. The poor performance of the CQ and TPO
initiators in these samples was consistent irrespective of the presence or absence of an UV absorber.
c) Hydroxyalkyl methacrylate polymers (Example 1) t5 The TPO-initiated system cured very well even after the shortest exposure time (15 minutes), while the CQ-initiated system did not cure well until one hour of exposure - and even at this exposure, extractables were three times higher than the TPO-cured system at the shortest exposure time. 2-Hydroxyethyl 2o methacrylate (HEMA) is typically rapidly cured - yet the CQ-initiated system still gave a sluggish cure.
d) Vinyl monomers (Examples 2 - 4) Z5 Neither the styrene (Ex. 4) nor the NVP/styrene samples (Ex. 2) cured well with any of the initiators. The NVP sample (Ex. 3) appeared to cure poorly with CQ
but well with TPO. The NVP sample apparently dissolved when extracted with acetone, however. It is presumed that this result may be explained by a non-cross-linked nature of the polyvinylpyrrolidone.
The superior results obtained with TPO are surprising in view of the fact that CQ has a greater absorbency in the blue-light region than does TPO (see Figures 1 and 2), and thus would be expected to have the higher activity.
Additionally, with reference to Fig. 3 which shows the UV-visible spectrum of the UV-absorber used in the Examples, the fact that TPO gave results superior to CQ
in the presence of the UV-absorber is surprising. The absorption bands for the UV-chromophore (oMTP) and CQ are well separated (compare Figs. 2 and 3), whereas there is appreciable spectral overlap between the oMTP and TPO
compounds (compare Figs. 1 and 3). Thus, the UV-chromophore would be expected to interfere significantly with the ability of TPO to be activated by the light source, but not CQ. The opposite was observed (Compare Examples 9 and ,0 11 with Examples 12 and 14).
The effect of cure time and radiation flux on the level of extractables and mechanical properties was examined for the composition of Example 7. In all cases, the concentration of the photoinitiator was 0.4%. This level of photoinitiator ,5 was chosen because discoloring (yellowing) was observed at greater concentrations of CQ initiator. The results are shown below in Table 3.
Extractables IOUslab Stress Modulus Lamp%Cure Time CQ TPO %AU** Tg psi %Strainpsi GE-15 min ~ 100 10.7 51.1 12.2/12.7 878 629 224 GE-30 min ~ 100 2.9 44.9 12.3112.2 979 618 229 GE-60 min ~ 100 1.8 45.1 12.8/12.2 1014 611 266 CU-15 min ~ 100 4.3 46.6 11.8 908 657 232 CU-30 min --100 1.9 46.6 11.8 975 654 250 CU~O min 40.6 1.5 45.6 12.9 1077 676 269 CU-120 min 10.4 - --- ~ ~ _ *Lamp: GE = GE 20 watt/24" blue CU = Heraeus fluorescent lamp; Kuizer Palatray CU blue-light unit zo **AU = weight percent of acetone uptake: slabs placed overnight in acetone (room temperature) then patted dry and weighted on WR-129 scale within , Mettler 15 seconds.
To evaluate the relative reactivity of TPO and CQ initiators, Example #7 was prepared using a 0.4% (w/w) level of each initiator. The 0.4%
concentration for the initiator was selected based on the fact that the use of higher levels with CQ resulted in color formation and increased levels of extractables; the range of CQ reported in the literature is typically 0.1 % to 0.5%. Two radiation fluxes were used: 3 and 14 mW/cm2. The 3 mW/cm2 intensity was produced by the GE 20 watt, blue fluorescent lamp; the 14 mW/cm2 intensity was produced by the Palatray CU blue-light unit. The level of acetone extractables and mechanical properties were measured as a function of flux and cure time. Based on ,o extractable levels, it took the CQ more than 37 times longer to achieve the same level as TPO ( i.e., 15 minl3 mW for TPO = 120 min/14 mW/cm2 for CQ). After 60 minutes @ 14m W/cmZ the CQ initiated monomer still gave more than 40%
extractables. The TPO initiated system, on the other hand, achieved near optimal extractable levels (< 5%) after less than a 30-minute exposure at 3 mWlcm2.
,5 These results are surprising in light of the fact that the CQ has the greater absorption in the blue light region of the spectrum.
The invention having now been fully described, it should be understood that it may be embodied in other specific forms or variations without departing from its 2o spirit or essential characteristics. Accordingly, the embodiments described above are to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
The device materials of this invention are prepared by forming a mixture of the device-forming monomer{s) (monomer(s) of Formula I and any optional device-forming monomer), the UV-absorbing chromophore, and the benzoylphosphine 3° oxide initiator, along with any other suitable ingredients, in the desired proportions.
The mixture can then be introduced into a mold of suitable shape to form an ophthalmic device, and the polymerization carried out by exposure to blue-light.
s 'I
The device materials of the present invention are preferably cured in vitro.
Blue-light sources are commeraally available and include: the Palatray CU
blue-light unit (available from Heraeus Kufzer, Inc., Irvine, California), the Fusion s F450*blue light system (available from TEAMCO, Richardson, Texas) and the GE
24" blue fluorescent lamp (available from General Electric Company, U.S.). A
preferred blue-light source is the Palatray CU blue-light unit. Suitable blue-Ight sounds emit light in the 400 - 500 nm range sufficient to activate benzoylphosphine oxide initiators. Suitable blue-light sources include sunlight and standard white ,o fluorescent light bulbs, for example, though these sources would require longer exposure times to achieve complete cures than sources which emit light in the - 500 nm range at higher intensities.
The intensity of the blue light from the blue-light source is preferably from ,s about 1 to about 40 mWlcmZ. An intensity in the blue-light region of from about 10 to about 15 mWlcm2 is more preferred. If the intensity of blue-light is too great, in addition to shrinkage problems created during curing, the device material may turn yellow or otherwise become discolored.
o The length of time necessary for the device materials of the present invention to be exposed to a blue light source in order to be cured will depend upon a variety of factors, including the reactivity of the device material ingredients, the size and mass of the sample to be cured, the initiator concentration and the intensity of the blue-light source. In general, for individually cast devices, exposure times will range from about 5 minutes to about 4 hours, preferably from about minutes to about 2 hours. Attempting to cure.the materials too quickly may result in compnxnised optical properties; too rapid cross-linking may cause shrinkage-related stresses within the cured polymer that distort the surface of the device as they are relieved.
For exposure times of about an hour or less, it is preferred that the molds containing the device materials not be opened immediately after being exposed to *Trade-mark g blue-light. Leaving the molds unopened for approximately one hour allows residual curing reactions to be completed.
The ophthalmic device materials prepared according to the present invention may be used to make almost any type of ophthalmic lens, including contact lenses, intracorneal lenses and intraocular lenses. Ophthalmic lenses constructed of the disclosed materials can be of any design, but are preferably intraocular lenses (IOLs) capable of being rolled or folded and inserted through a relatively small incision. For example, the IOLs can be of what is known as a one piece or ,0 multipiece design. Typically, an IOL comprises an optic and at least one haptic.
The optic is that portion which serves as the lens and the haptics are attached to the optic and are like arms that hold the optic in its proper place in the eye. The optic and haptic(s) can be of the same or different material. Haptics may be attached to the optic using conventional techniques. In a single piece lens, the ,5 optic and the haptics are formed out of one piece of material. Depending on the material, the haptics are then cut, or lathed, out of the material to produce the IOL.
In addition to ophthalmic lenses, the materials prepared according to the methods of the present invention may also be used to make other ophthalmic devices including, but not limited to, keratoprostheses and corneal inlays or rings.
Molding and drilling operations are easily carried out if the device, e.g., an IOL optic, is molded between two polypropylene mold halves. The mold containing the cured device material is then placed on a lathe and the desired shape is lathe cut. The mold may then be easily mounted to carry out any drilling operations prior Z5 to removing the mold halves. Both the lathing and drilling operations may be facilitated by cooling the mold/device in a freezer to less than 10°C
and preferably less than 0°C prior to each of these operations. If premature release of one or both mold halves occurs, it may be necessary to use clamps or alternative mold materials or to treat the surface of the mold halves.
The invention will be further illustrated by the following examples which are intended to be illustrative, but not limiting.
*rB
EXAMPLES
The following mixtures shown below in Table 1 were prepared and transferred into molds for curing:
Table 1 PEMA - . 1pp30 POEA - 89.6 89.587.8 87.7 - 10 99.655 10 97.85 -EGDMA 0.350.35 0.350.350.350.35 BDDA 1 1 3.23.2 OMTP 1.81.8 1.8 1.8 1.8 PEA = 2-phenylethylacrylate s PEMA = 2-phenylethylmethacrylate MMA = methyl methacrylate HEMA = 2-hydroxyethylmethacrylate POEA = 2-phenoxyethyl acrylate (passed through basic alumina) HA = N-hexyl acrylate (passed through basic alumina) ,o NVP = N-vinyl pyrrolidone (passed through acidic alumina) EGDMA = ethyleneglycoldimethacrylate BDDA = 1,4-butanediol diacrylate OMTP = o-Methyl. Tinuvin P (2-(3'-methallyl-2'-hydroxy-5'-methyl phenyl)-benzotriazole) ,s "All values are expressed as parts by weight.
The compositions of Examples 1 - 14 were then cured according to each of three cure profiles as indicated below in Table 2: a thermal cure system using the thermal initiator Perkadox 16 and a curing temperature of 70 °C for 1 hour; and two 2o photoinitiators, camphorquinone and Lucirin~ TPO, respectively, using a blue-light source with exposure times of 15, 30 and 60 minutes. After completing the cure profile, all molds were left uriopened for approximately 1 hour. After opening the molds, physical appearance was recorded. "Liquid" indicates that the sample did not appear to cure to any significant extent. "Gel-slime" indicates that the sample 25 cured to some extent, but still appeared to be primarily a liquid. "Gel"
indicates that the sample cured to a loose solid. "Solidn indicates that the sample appeared to cure thoroughly or completely.
After the physical appearance of each sample was recorded, the samples rated "solid" were extracted in acetone. These samples were weighed ("initial weight"), placed into hot (near boiling) acetone for two hours, and then dried for two hours in an air-circulating oven. After drying, the samples were weighed again ("final weight"). The percent extractables were calculated as follows:
(initial weight -final weight)/(initial weight) x 100. For samples rated "liquid," no weight measurements were taken; % extractables for these samples was estimated to be 100%. For samples rated "Gel-slime" or "Gel" no weight measurements were taken;
,° % extractables for these samples was estimated to be > 95%. The physical appearance and the level of extractables for each of the samples of Table 1 are shown below in Table 2.
Cure Profile1 hrI70C 15 15 I
oven I 30 /
30 60 min l 14 mW/cm2 60 blue min li ht mW/cm2 blue light Initiator Perkadox-16dl-Camphorquinone Lucirin~
(concentration)(1 %) (0.5%) TPO
(0.5%) Example Cure esults # R
1 solid gel-slime/ solid/
el-slime! solid/
solid solid 2 liquid liquidlli liquid/li uidlliquid uidlli uid 3 liquid eU solid/
eU solid/
e! solid 4 liquid IiquidAiquidlliquid liquid/liquidlliquid solid liquid/liquidlliquid liquidlliquid/liquid 6 solid liquidlliquid/ solid!
e! solid/
solid 7 solid solid/ solid/
solid/ solid) solid solid 8 solid gel/gel/solid solid/
solid/
solid 9 solid solid/ solid!
solid/ solid/
solid solid solid geI/geU gel/ eU
e! e!
11 solid solid/ solid!
solid! solid!
solid solid 12 solid solid/ solid!
solid/ solid) solid solid 13 solid liquid/liquidlliquid gellgeUgel 14 solid solid/ solid!
solid/ solid/
solid solid ACETONE "
EXTRACTABLES
EXAMPLE
#
1 <1 > > 95 3.0 <1 <1 <1 5 8.0 100 100 100 100 100 100 6 0.9 100 100 ND 19.9 10.7 12.1 7 8.5 ND ND 18.8 3.2 1.9 1.9 8 6.7 >95 >95 8.8 3.9 2.2 2.1 9 8.6 6.2 6.6 6.4 4.4 5.5 3.8 10 9.2 >95 >95 >95 >95 >95 >95 11 7.5 6.8 5.5 5.3 4.4 3.9 4.1 12 20.4 48.3 22.2 11.8 6.1 5.9 5.9 13 13.2 100 100 100 >95 >95 >95 14 21.5 46.1 35.1 33.4 7.3 6.8 7.1 ~rvu = not aetermmea The results of Table 2 are discussed with reference to the type of device-forming monomers) present in the samples:
a) Aryl (meth)acrylate based polymers (Examples 6 - 9, 11, 12, and 14) ,o When the samples lacked an UV-absorber (Examples 9 and 11 ), they cured similarly in the presence of either blue-light initiator, camphorquinone ("CQ") or Lucirin~ TPO ("TPO"), with the TPO-cured samples showing somewhat lower extractables. In contrast, when the samples contained an UV-absorber (Examples 6 - 8, 12 and 14), the CQ initiator gave much poorer results: in all such cases, the extractables were significantly higher for the samples cured with CQ
than with TPO.
b~ Alkyl (m~th)acrylate based polymers (Examples 5, 10 and 13) Although the samples of Examples 5, 10 and 13 all cured to some extent when the thermal initiator was used, all of these samples cured very poorly when either ,o CQ or TPO was used as an initiator. The poor performance of the CQ and TPO
initiators in these samples was consistent irrespective of the presence or absence of an UV absorber.
c) Hydroxyalkyl methacrylate polymers (Example 1) t5 The TPO-initiated system cured very well even after the shortest exposure time (15 minutes), while the CQ-initiated system did not cure well until one hour of exposure - and even at this exposure, extractables were three times higher than the TPO-cured system at the shortest exposure time. 2-Hydroxyethyl 2o methacrylate (HEMA) is typically rapidly cured - yet the CQ-initiated system still gave a sluggish cure.
d) Vinyl monomers (Examples 2 - 4) Z5 Neither the styrene (Ex. 4) nor the NVP/styrene samples (Ex. 2) cured well with any of the initiators. The NVP sample (Ex. 3) appeared to cure poorly with CQ
but well with TPO. The NVP sample apparently dissolved when extracted with acetone, however. It is presumed that this result may be explained by a non-cross-linked nature of the polyvinylpyrrolidone.
The superior results obtained with TPO are surprising in view of the fact that CQ has a greater absorbency in the blue-light region than does TPO (see Figures 1 and 2), and thus would be expected to have the higher activity.
Additionally, with reference to Fig. 3 which shows the UV-visible spectrum of the UV-absorber used in the Examples, the fact that TPO gave results superior to CQ
in the presence of the UV-absorber is surprising. The absorption bands for the UV-chromophore (oMTP) and CQ are well separated (compare Figs. 2 and 3), whereas there is appreciable spectral overlap between the oMTP and TPO
compounds (compare Figs. 1 and 3). Thus, the UV-chromophore would be expected to interfere significantly with the ability of TPO to be activated by the light source, but not CQ. The opposite was observed (Compare Examples 9 and ,0 11 with Examples 12 and 14).
The effect of cure time and radiation flux on the level of extractables and mechanical properties was examined for the composition of Example 7. In all cases, the concentration of the photoinitiator was 0.4%. This level of photoinitiator ,5 was chosen because discoloring (yellowing) was observed at greater concentrations of CQ initiator. The results are shown below in Table 3.
Extractables IOUslab Stress Modulus Lamp%Cure Time CQ TPO %AU** Tg psi %Strainpsi GE-15 min ~ 100 10.7 51.1 12.2/12.7 878 629 224 GE-30 min ~ 100 2.9 44.9 12.3112.2 979 618 229 GE-60 min ~ 100 1.8 45.1 12.8/12.2 1014 611 266 CU-15 min ~ 100 4.3 46.6 11.8 908 657 232 CU-30 min --100 1.9 46.6 11.8 975 654 250 CU~O min 40.6 1.5 45.6 12.9 1077 676 269 CU-120 min 10.4 - --- ~ ~ _ *Lamp: GE = GE 20 watt/24" blue CU = Heraeus fluorescent lamp; Kuizer Palatray CU blue-light unit zo **AU = weight percent of acetone uptake: slabs placed overnight in acetone (room temperature) then patted dry and weighted on WR-129 scale within , Mettler 15 seconds.
To evaluate the relative reactivity of TPO and CQ initiators, Example #7 was prepared using a 0.4% (w/w) level of each initiator. The 0.4%
concentration for the initiator was selected based on the fact that the use of higher levels with CQ resulted in color formation and increased levels of extractables; the range of CQ reported in the literature is typically 0.1 % to 0.5%. Two radiation fluxes were used: 3 and 14 mW/cm2. The 3 mW/cm2 intensity was produced by the GE 20 watt, blue fluorescent lamp; the 14 mW/cm2 intensity was produced by the Palatray CU blue-light unit. The level of acetone extractables and mechanical properties were measured as a function of flux and cure time. Based on ,o extractable levels, it took the CQ more than 37 times longer to achieve the same level as TPO ( i.e., 15 minl3 mW for TPO = 120 min/14 mW/cm2 for CQ). After 60 minutes @ 14m W/cmZ the CQ initiated monomer still gave more than 40%
extractables. The TPO initiated system, on the other hand, achieved near optimal extractable levels (< 5%) after less than a 30-minute exposure at 3 mWlcm2.
,5 These results are surprising in light of the fact that the CQ has the greater absorption in the blue light region of the spectrum.
The invention having now been fully described, it should be understood that it may be embodied in other specific forms or variations without departing from its 2o spirit or essential characteristics. Accordingly, the embodiments described above are to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
Claims (20)
1. ~A method of preparing a foldable, acrylic, high refractive index ophthalmic device material comprising the steps of:
a) preparing a device-forming mixture of a benzoylphosphine oxide photoinitiator, a W-absorbing chromophore and one or more device-forming monomers having the structure (I) where X is H or CH3;
m is an integer from 0-10;
Y is a single bond, O, S, or NR wherein R is H, CH3, C n H2n+1, wherein n is an integer from 1-10, iso OC3H7, C6H5, or CH2C6H5; and Ar is any aromatic ring which can be unsubstituted or substituted with H, CH3, C2H5, n-C3H7, iso-C3H7, OCH3, C6H11.
Cl, Br, C6H5, or CH2C6H5;
and b) exposing the mixture to a blue-light source for a period of time sufficient to cure the device material.
a) preparing a device-forming mixture of a benzoylphosphine oxide photoinitiator, a W-absorbing chromophore and one or more device-forming monomers having the structure (I) where X is H or CH3;
m is an integer from 0-10;
Y is a single bond, O, S, or NR wherein R is H, CH3, C n H2n+1, wherein n is an integer from 1-10, iso OC3H7, C6H5, or CH2C6H5; and Ar is any aromatic ring which can be unsubstituted or substituted with H, CH3, C2H5, n-C3H7, iso-C3H7, OCH3, C6H11.
Cl, Br, C6H5, or CH2C6H5;
and b) exposing the mixture to a blue-light source for a period of time sufficient to cure the device material.
2. ~The method of Claim 1 wherein the monomer of structure (I) is selected from the group consisting of: 2-phenoxyethyl acrylate; 2-phenylethylthio acrylate; 2-phenylethylamino acrylate; phenyl acrylate; benzyl acrylate;
2-phenylethyl acrylate; 3-phenylpropyl acrylate; 4-phenylbutyl acrylate; 4-methylphenyl acrylate; 4-methylbenzyl acrylate; 2-2-methylphenylethyl acrylate; 2-3-methylphenylethyl acrylate; 2-4-methylphenylethyl acrylate;
and their corresponding methacrylates.
2-phenylethyl acrylate; 3-phenylpropyl acrylate; 4-phenylbutyl acrylate; 4-methylphenyl acrylate; 4-methylbenzyl acrylate; 2-2-methylphenylethyl acrylate; 2-3-methylphenylethyl acrylate; 2-4-methylphenylethyl acrylate;
and their corresponding methacrylates.
3. ~The method of Claim 1 wherein X is H; m is an integer from 2-4; Y is a single bond or O; and Ar is phenyl.
18a
18a
4. The method of Claim 3 wherein the monomer of structure (I) is selected from the group consisting of: 2-phenylethyl acrylate: 2-phenoxyethyl acrylate; 3-phenylpropyl acrylate; 3-phenoxypropyl acrylate; 4-phenylbutyl acrylate; and 4-phenoxybutyl acrylate.
5. The method of Claim 1 wherein the device material has a glass transition temperature no greater than 25 °C and an elongation of at least 150%.
6. The method of Claim 1 wherein the total amount of monomer of structure (I) present in the device material is at least 50% (w/w).
7. The method of Claim 6 wherein the total amount of monomer of structure (I) present in the device material is at least 70% (w/w).
8. The method of Claim 7 wherein the total amount of monomer of structure (I) present in the device material is at least 80% (w/w).
9. The method of Claim 6 wherein the device-forming mixture further comprises one or more additional device-forming monomers selected from the group consisting of: C1- C8 alkylacrylates; C1 - C8 cycloalkylacrylates; N-alkylacrylamides, where alkyl=C1-C4; phenoxyalkylacrylates, where alkyl=C1-C8;
glycerylacrylate; polyethyleneoxide mono- and diacrylates; 2-hydroxyethylacrylate; C1-C8 alkylmethacrylates; C1-C8 cycloalkylmethacrylates; N-alkylmethacrylamides, where alkyl=C1-C4; phenoxyalkylmethacrylates, where alkyl=C1-C8;
glycerylmethacrylate;
polyethyleneoxide mono- and dimethacrylates; 2-hydroxyethylmethacrylate; and N-vinylpyrrolidone.
glycerylacrylate; polyethyleneoxide mono- and diacrylates; 2-hydroxyethylacrylate; C1-C8 alkylmethacrylates; C1-C8 cycloalkylmethacrylates; N-alkylmethacrylamides, where alkyl=C1-C4; phenoxyalkylmethacrylates, where alkyl=C1-C8;
glycerylmethacrylate;
polyethyleneoxide mono- and dimethacrylates; 2-hydroxyethylmethacrylate; and N-vinylpyrrolidone.
10. The method of Claim 10 wherein the total amount of additional device-forming monomer is 45% (w/w) or less.
11. The method of Claim 1 wherein the benzoylphosphine oxide initiator is selected from the group consisting of: 2,4,6-trimethyl-benzoyldiphenylophosphine oxide; bis-(2,6-dichlorobenzoyl)-4-N-propylphenyl-phosphine oxide; and bis-(2,6-dichlorobenzoyl)-4-N-butylphenylphosphine oxide.
12. The method of Claim 11 wherein the benzoylphosphine oxide initiator is 2,4,6-trimethyl-benzoyldiphenylophosphine oxide.
13. The method of Claim 1 wherein the amount of benzoylphosphine oxide initiator is less than about 3% (w/w).
14. The method of Claim 13 wherein the amount of benzoylphosphine oxide initiator is about 1% (w/w).
15. The method of Claim 1 wherein the device-forming mixture further comprises one or more copolymerizable cross-linking monomers.
16. The method of Claim 1 wherein the blue-light source has an intensity of from about 1 to about 40 mW/cm2 and the period of time in which the device-forming mixture is exposed to the blue-light source is from about 5 minutes to about 4 hours.
17. The method of Claim 1 wherein the blue-light source has an intensity of from about 10 to about 15 mW/cm2.
18. The method of Claim 1 wherein the device-forming mixture comprises 2-phenylethyl acrylate and 2-phenylethyl methacrylate.
19. The method of Claim 1 wherein the device-forming mixture comprises 2-phenylethyl acrylate and 2-hydroxyethyl methacrylate.
20. The method of Claim 1 wherein the device-forming mixture comprises phenoxyethyl acrylate and N-hexyl acrylate.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US08/908,229 US5891931A (en) | 1997-08-07 | 1997-08-07 | Method of preparing foldable high refractive index acrylic ophthalmic device materials |
US08/908,229 | 1997-08-07 | ||
PCT/US1998/014419 WO1999008136A1 (en) | 1997-08-07 | 1998-07-14 | Method of preparing foldable high refractive index acrylic ophthalmic device materials |
Publications (2)
Publication Number | Publication Date |
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CA2279452A1 CA2279452A1 (en) | 1999-02-18 |
CA2279452C true CA2279452C (en) | 2003-09-23 |
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CA002279452A Expired - Fee Related CA2279452C (en) | 1997-08-07 | 1998-07-14 | Method of preparing foldable high refractive index acrylic ophthalmic device materials |
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US (1) | US5891931A (en) |
EP (1) | EP1002244B1 (en) |
JP (1) | JP2002511012A (en) |
CN (1) | CN1140817C (en) |
AR (1) | AR012512A1 (en) |
AT (1) | ATE233409T1 (en) |
AU (1) | AU724873B2 (en) |
BR (1) | BR9811860B1 (en) |
CA (1) | CA2279452C (en) |
DE (1) | DE69811675T2 (en) |
DK (1) | DK1002244T3 (en) |
ES (1) | ES2191947T3 (en) |
PT (1) | PT1002244E (en) |
WO (1) | WO1999008136A1 (en) |
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- 1998-07-14 PT PT98934449T patent/PT1002244E/en unknown
- 1998-07-14 WO PCT/US1998/014419 patent/WO1999008136A1/en active IP Right Grant
- 1998-07-14 CA CA002279452A patent/CA2279452C/en not_active Expired - Fee Related
- 1998-07-14 AT AT98934449T patent/ATE233409T1/en active
- 1998-07-14 BR BRPI9811860-9A patent/BR9811860B1/en not_active IP Right Cessation
- 1998-07-14 JP JP51213499A patent/JP2002511012A/en active Pending
- 1998-07-14 ES ES98934449T patent/ES2191947T3/en not_active Expired - Lifetime
- 1998-07-14 DK DK98934449T patent/DK1002244T3/en active
- 1998-08-06 AR ARP980103901A patent/AR012512A1/en active IP Right Grant
Also Published As
Publication number | Publication date |
---|---|
ATE233409T1 (en) | 2003-03-15 |
US5891931A (en) | 1999-04-06 |
CA2279452A1 (en) | 1999-02-18 |
EP1002244A1 (en) | 2000-05-24 |
EP1002244B1 (en) | 2003-02-26 |
BR9811860B1 (en) | 2009-05-05 |
BR9811860A (en) | 2000-08-15 |
AR012512A1 (en) | 2000-10-18 |
DE69811675T2 (en) | 2003-09-18 |
AU724873B2 (en) | 2000-10-05 |
ES2191947T3 (en) | 2003-09-16 |
DE69811675D1 (en) | 2003-04-03 |
CN1140817C (en) | 2004-03-03 |
CN1251174A (en) | 2000-04-19 |
DK1002244T3 (en) | 2003-05-26 |
WO1999008136A1 (en) | 1999-02-18 |
JP2002511012A (en) | 2002-04-09 |
AU8396498A (en) | 1999-03-01 |
PT1002244E (en) | 2003-06-30 |
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