# Patent

## Title
Ophthalmic lens

## Abstract

An ophthalmic lens which gives excellent wearing comfort required for its use as a contact lens, and which has sufficiently high flexibility and an adequate degree of deformation recovery property required for its use as an intraocular lens. The ophthalmic lens is formed of a polymer having a young's modulus of 0.3-1.0 MPa and a stress relaxation rate of 10-20%.

## Background
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of the International Application No. PCT/JP2013/083671 filed on Dec. 16, 2013, the entireties of which are incorporated herein by reference.


BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to an ophthalmic lens such as a contact lens and an intraocular lens.
Description of Related Art
Various properties are required for an ophthalmic lens such as a contact lens and an intraocular lens. For instance, the contact lens which is worn on a sensitive cornea of the eye is intrinsically required to give excellent wearing comfort, so that the wearer is less likely to feel the contact lens as a foreign object. On the other hand, in recent years, development of a novel intraocular lens formed of a lens material (polymer) having excellent flexibility has been desired, since the intraocular lens formed of such a highly flexible lens material (polymer) can be folded into a small piece, and inserted into the eye through a small incision.
Further, in recent years, the contact lens, in particular, is required to exhibit more excellent oxygen permeability than that of the conventional contact lens, so that a sufficient amount of oxygen is supplied to the cornea.
For instance, it is widely known that a silicone polymer having a siloxane main chain including a siloxane unit as a repeating unit has excellent flexibility and excellent oxygen permeability. The silicone polymer has been used as a material of various kinds of ophthalmic lens including the contact lens. For instance, a copolymer (silicone hydrogel) of a polysiloxane-based macromonomer in which a polymerizable group is bonded to the siloxane main chain, and a hydrophilic monomer such as N-vinylpyrrolidone and dimethyl acrylamide gives a highly oxygen-permeable water-absorptive lens. Accordingly, various studies have been made and various techniques have been proposed regarding the ophthalmic lens (particularly, contact lens) formed of the silicone hydrogel, and a method of production of such an ophthalmic lens. Specifically, a silicone hydrogel contact lens is proposed in JP-T-2008-511870, an ophthalmic lens for long-term wearing is proposed in JP-A-2010-20330 and a method of production of a silicone hydrogel contact lens is proposed in JP-T-2012-513042.
However, it cannot be said that the conventional polysiloxane-based macromonomer such as those described in the above-indicated Patent Documents 1 to 3 exhibits sufficiently high compatibility with a hydrophilic monomer. Therefore, in production of the ophthalmic lens using the conventional polysiloxane-based macromonomer, and the hydrophilic monomer or the like, there is a risk that when the components are mixed together, the mixture is clouded or whitened, or a polymer obtained by polymerization is clouded or whitened, depending on a combination of the components, giving rise to a problem that the combination of the components is limited in order to obtain a transparent ophthalmic lens.
On the other hand, as for the intraocular lens, there is a problem of so-called glistening, which is a phenomenon in which white spots appear within the intraocular lens when it is implanted in the eye and hydrated, and transparency of the intraocular lens is considerably lowered or lost. Under the above-described circumstances, Patent Document 4 (Japanese Patent No. 3641110) proposes an intraocular lens formed by copolymerization of a plurality of monomer components having excellent compatibility with each other, to restrict occurrence of the glistening.
SUMMARY OF THE INVENTION
The present invention was made in view of the background art described above. It is an object of the invention to provide an ophthalmic lens which gives excellent wearing comfort required for its use as the contact lens, and which has sufficiently high flexibility and an adequate degree of deformation recovery property required for its use as the intraocular lens.
Under the above-described circumstances, the inventor of the present invention made intensive studies, and found that the above-described object can be achieved by an ophthalmic lens formed of a polymer having a young's modulus and a stress relaxation rate, which are held within respective predetermined ranges. The present invention was completed based on this finding.
Namely, the principle of the present invention is an ophthalmic lens formed of a polymer having a young's modulus of 0.3-1.0 MPa and a stress relaxation rate of 10-20%.
In a first preferable form of the ophthalmic lens according to the invention, a value α calculated according to the following formula (A) is held within a range from 0.02 to 0.10:

α=E/r  (A)

wherein E represents the young's modulus (MPa) of the polymer of the ophthalmic lens, and r represents the stress relaxation rate (%) of the polymer.
In a second preferable form of the ophthalmic lens according to the invention, the polymer is obtained from a polymerizable composition including a polysiloxane-based macromonomer having at least one polymerizable group and a polysiloxane chain having a siloxane unit as a repeating unit.
In a third preferable form of the ophthalmic lens according to the invention, the polysiloxane-based macromonomer has: 1) a polyoxyethylene chain having an oxyethylene group as a repeating unit, wherein a number of repetition of the oxyethylene group is “a” (“a” is an integer not smaller than two); and 2) a polyoxyalkylene chain having an oxyalkylene group other than the oxyethylene group as a repeating unit, wherein a number of repetition of the oxyalkylene group is “b” (“b” is an integer not smaller than two), and wherein a value β calculated according to the following formula (B) is held within a range from 0.5 to 5.0:

β=n/(a+b)  (B)

wherein n represents a total number of Si atoms in a molecule of the polysiloxane-based macromonomer.
In a fourth preferable form of the ophthalmic lens according to the invention, an HLB value of the polysiloxane-based macromonomer calculated according to the following formula (C) is held within a range from 0.7 to 6.0:

[HLB value]=WE/5  (C)

wherein WE represents a weight fraction (wt %) of the oxyethylene group in the molecule of the polysiloxane-based macromonomer.
In a fifth preferable form of the ophthalmic lens according to the invention, the number “a” of repetition of the oxyethylene group is within a range from 4 to 15.
In a sixth preferable form of the ophthalmic lens according to the invention, the polyoxyalkylene chain is a polyoxypropylene chain having an oxypropylene group as a constituent unit.
In a seventh preferable form of the ophthalmic lens according to the invention, a number of repetition of the oxypropylene group is within a range from 5 to 16.
In an eighth preferable form of the ophthalmic lens according to the invention, the at least one polymerizable group is bonded to the polysiloxane chain constituting a main chain of a molecule of the polysiloxane-based macromonomer, through at least one urethane bond.
As described above, the ophthalmic lens according to the present invention is formed of the polymer having the young's modulus and the stress relaxation rate, which are held within the respective predetermined ranges. Accordingly, the ophthalmic lens according to the invention gives excellent wearing comfort required for its use as the contact lens, and has sufficiently high flexibility and an adequate degree of deformation recovery property required for its use as the intraocular lens.


DETAILED DESCRIPTION OF THE INVENTION
By the way, an ophthalmic lens according to the invention is formed of a polymer having a young's modulus (E) of 0.3-1.0 MPa and a stress relaxation rate (r) of 10-20%. In the case where the young's modulus (E) of the polymer of the ophthalmic lens is less than 0.3 MPa and/or in the case where the stress relaxation rate (r) of the polymer is more than 20%, the ophthalmic lens has a low degree of stability of its shape, giving rise to extreme difficulty in handling of the ophthalmic lens and a risk of failure of the ophthalmic lens to exhibit a sufficiently high degree of optical performance. On the other hand, in the case of a contact lens, for example, if the young's modulus (E) of the polymer is more than 1.0 MPa and/or in the case where the stress relaxation rate (r) of the polymer is less than 10%, there is a risk of deterioration of wearing comfort of the contact lens.
The young's modulus (E) of the polymer (lens material) of the ophthalmic lens is often used as a measure which indicates a degree of flexibility of the lens material. The contact lens formed of a lens material having a low young's modulus generally tends to give excellent wearing comfort. On the other hand, the stress relaxation rate (r) is defined by the inventor of the present invention, as a measure which indicates a degree of relaxation of a stress. In this respect, it is noted that the relaxation of the stress means a phenomenon in which the stress decreases with a passage of time, when a certain degree of strain is given to an object. In the present invention, the stress relaxation rate (r) is calculated according to a formula (D) given below.

[Stress relaxation rate: r (%)]=[(L1−L2)/L1]×100  Formula (D)

The values L1 and L2 in the above-indicated formula (D) are obtained by a tensile test conducted on the polymer of the ophthalmic lens. Specifically described, the tensile test is conducted at a test speed of 20 mm/min, on a test piece which is formed of the polymer of the ophthalmic lens, and which has a configuration (of a dumbbell) shown in FIG. A. 2 of JIS-K-7162-1994 “Plastics—Determination of tensile properties—Part 2: Test conditions for moulding and extrusion plastics”. When a measured value of the stress reaches 0.1N, an operation of pulling the test piece is immediately stopped. The value L1 is defined as the stress measured immediately after stopping the pulling operation, and the value L2 is defined as the stress measured after 30 seconds has passed after the moment of stopping the pulling operation. Further, the young's modulus (E) defined in the present invention is obtained when the stress is within a range of 0.01-0.10N in the tensile test. In the case where the polymer of the ophthalmic lens is a water-absorptive material such as a hydrogel of a water-absorptive soft contact lens, for example, a test piece having the above-described configuration is formed by using the polymer which has been immersed in water or an isotonic sodium chloride solution, and hydrated and swelled to the state of equilibrium, and the young's modulus and the stress relaxation rate defined in the present invention are obtained by conducting the tensile test on the test piece under the above-described conditions, in the water or the isotonic sodium chloride solution which was used for the hydration of the polymer.

As described above, the polymer of the ophthalmic lens according to the present invention has the young's modulus and the stress relaxation rate, which are held within the respective predetermined ranges described above. More preferably, the polymer of the ophthalmic lens according to the present invention is configured such that a value α calculated according to a formula (A) given below is held within a range from 0.02 to 0.10.

α=E/r  (A)

In the above-indicated formula (A), E represents the young's modulus (MPa) of the polymer of the ophthalmic lens, and r represents the stress relaxation rate (%) of the polymer.

The value α is a parameter found by the inventor of the present invention as a result of intensive studies on the ophthalmic lens such as the contact lens and the intraocular lens, and indicates the wearing comfort of the contact lens and the flexibility and a deformation recovery property of the intraocular lens, in particular. The ophthalmic lens formed of the polymer configured such that the value α is within the range from 0.02 to 0.10 gives more excellent wearing comfort where it is used as the contact lens, and more effectively exhibits a sufficiently high degree of flexibility and an adequate degree of deformation recovery property where it is used as the intraocular lens.
As described above, the ophthalmic lens according to the present invention is formed of the polymer having the young's modulus and the stress relaxation rate, which are held within the respective predetermined ranges described above. It is preferable that the above-indicated polymer is obtained from a polymerizable composition including a polysiloxane-based macromonomer having at least one polymerizable group and a polysiloxane chain having a siloxane unit as a repeating unit. It is possible to use any polysiloxane-based macromonomer, as long as the polysiloxane-based macromonomer permits production of the polymer having the young's modulus and the stress relaxation rate, which are held within the respective predetermined ranges described above. In the present invention, it is particularly advantageous to use the polysiloxane-based macromonomer which has: 1) a polyoxyethylene chain having an oxyethylene group as a repeating unit, wherein a number of repetition of the oxyethylene group is “a” (“a” is an integer not smaller than two); and 2) a polyoxyalkylene chain having an oxyalkylene group other than the oxyethylene group as a repeating unit, wherein a number of repetition of the oxyalkylene group is “b” (“b” is an integer not smaller than two), and which is configured such that a value β calculated according to a formula (B) given below is held within a range from 0.5 to 5.0.

β=n/(a+b)  (B)

In the above-indicated formula (B), n represents a total number of Si atoms in the molecule of the polysiloxane-based macromonomer.

The polysiloxane-based macromonomer described above has a specific structure, so that the polysiloxane-based macromonomer can exhibit good compatibility with respect to both of a hydrophobic monomer and a hydrophilic monomer, which have been generally used in production of the ophthalmic lens. Namely, the polysiloxane-based macromonomer having the specific structure described above can be used in the production of various kinds of ophthalmic lens including the contact lens, in combination with the other components, which combination has been difficult to employ for the conventional polysiloxane-based macromonomer due to its poor compatibility with the other components (e.g. the hydrophilic monomer) and resultant risks of clouding of the ophthalmic lens to be obtained and occurrence of glistening in the case of use of the ophthalmic lens as the intraocular lens. Therefore, in the production of the ophthalmic lens according to the invention, freedom of choice of the combination of the components is increased, whereby various properties including the oxygen permeability of the ophthalmic lens can be further improved as compared with those of the ophthalmic lens produced by using the conventional polysiloxane-based macromonomer.
The above-described polysiloxane-based macromonomer advantageously used in the invention has the polymerizable group similar to that of the conventional polysiloxane-based macromonomer. Examples of the polymerizable group include an acryloyloxy group, a methacryloyloxy group, a vinyl group and an allyl group.
The polysiloxane-based macromonomer advantageously used in the invention has the polyoxyethylene chain in which the number of repetition of the oxyethylene group is two or more. In this respect, it is noted that where the number of repetition of the oxyethylene group is excessively large (excessively high), it is difficult to produce the macromonomer. Further, where the macromonomer has the polyoxyethylene chain having an excessively large (excessively high) number of repetition of the oxyethylene group, there is a risk that the ophthalmic lens obtained by using the macromonomer is fragile and has a low degree of strength. Therefore, the number of repetition of the oxyethylene group constituting the polyoxyethylene chain of the polysiloxane-based macromonomer used in the production of the ophthalmic lens according to the invention is selected preferably within a range from 4 to 15, and more preferably within a range from 4 to 10.
On the other hand, the polysiloxane-based macromonomer advantageously used in the invention has the polyoxyalkylene chain having the oxyalkylene group other than the oxyethylene group, as the repeating unit, in addition to the polyoxyethylene chain in which the number of repetition of the oxyethylene group is two or more. The oxyalkylene group of the polyoxyalkylene chain may be any one of various known oxyalkylene groups, as long as the oxyalkylene group does not hinder achievement of effects of the invention. Specific examples of the oxyalkylene group include an oxypropylene group and an oxybutylene group. It is particularly preferable that the polysiloxane-based macromonomer has a polyoxypropylene chain having the oxypropylene group (—CH(CH3)CH2O—) as the repeating unit.
The number of repetition of the oxyalkylene group other than the oxyethylene group is appropriately selected depending on the kind of the oxyalkylene group constituting the polyoxyalkylene chain. For instance, in the case of the polyoxyalkylene chain having the oxypropylene group as the repeating unit, it is preferable that the number of repetition of the oxypropylene group is within a range from 5 to 16.
The polysiloxane-based macromonomer advantageously used in the invention has the polyoxyethylene chain and the polyoxyalkylene chain other than the polyoxyethylene chain, as described above, and is configured such that the value β calculated according to the above-indicated formula (B) is held within the range from 0.5 to 5.0. The value β is a parameter found by the inventor of the present invention as a result of intensive studies on the polysiloxane-based macromonomer used for the ophthalmic lens, and indicates a degree of compatibility of the polysiloxane-based macromonomer with respect to both of a hydrophobic component such as the hydrophobic monomer, and a hydrophilic component such as the hydrophilic monomer. Specifically, the polysiloxane-based macromonomer configured such that the value β is held within the range from 0.5 to 5.0 exhibits excellent compatibility with respect to both of the hydrophobic component and the hydrophilic component, which are used in the production of the ophthalmic lens, whereas the polysiloxane-based macromonomer configured such that the value β is less than 0.5 or more than 5.0 exhibits poor compatibility with respect to the hydrophobic component and/or the hydrophilic component, resulting in failure to advantageously achieve the effects of the invention.
Further, the polysiloxane-based macromonomer described above is preferably configured such that an HLB value calculated according to a formula (C) given below is held within a range from 0.7 to 6.0. Where the HLB value is held within the predetermined range, the polysiloxane-based macromonomer can exhibit more excellent compatibility with respect to both of the hydrophobic monomer and the hydrophilic monomer. In this respect, it is noted the formula (C) given below is widely used to calculate the HLB value [“Shin-ban Kaimen Kasseizai Handobukku (New Edition of Surfactant Handbook)” p. 234, edited by Yoshida Tokiyuki and three others, issued by Kougaku Tosho K.K.].

[HLB value]=WE/5  (C)

In the above-indicated formula (C), WE represents a weight fraction (wt %) of the oxyethylene group in the molecule of the polysiloxane-based macromonomer.

The polysiloxane-based macromonomer used in the invention has, in its molecular chain, the polysiloxane chain having the siloxane unit as the repeating unit. Therefore, the ophthalmic lens according to the invention produced by using the polysiloxane-based macromonomer exhibits excellent oxygen permeability. Particularly in the case where the ophthalmic lens is produced by using the polysiloxane-based macromonomer having a structure in which the polymerizable group is bonded through one or more urethane bond(s) to the polysiloxane chain constituting the main chain of the molecule of the macromonomer, the presence of the urethane bond(s) having a high degree of elasticity or resilience gives advantages that the ophthalmic lens obtained by using the polysiloxane-based macromonomer is reinforced without deterioration of its excellent oxygen permeability owing to the siloxane chain, and imparted with elastic resilience, whereby the ophthalmic lens becomes less fragile and has an improved mechanical strength.
It is possible to use the above-described polysiloxane-based macromonomer as a raw material monomer of the ophthalmic lens according to the invention, as long as the polysiloxane-based macromonomer has the specific structure described above. An example of the structure of the polysiloxane-based macromonomer advantageously used in the production of the ophthalmic lens according to the invention is represented by a general formula (I) given below.
[Chemical Formula 1]

A1-Z1—U1—Z2—Z3—(—S1—U2—)n—S2—Z4—Z5—U3—Z6-A2  (I)

In the above-indicated general formula (I), A1 is a group represented by a general formula (II) given below, and A2 is a group represented by a general formula (III) given below.

Y21—R21—  (II)

—R22—Y22  (III)

In the above-indicated general formulas (II) and (III), both of Y21 and Y22 are polymerizable groups, and each of Y21 and Y22 represents an acryloyloxy group, a methacryloyloxy group, a vinyl group or an allyl group, independently of each other. On the other hand, each of R21 and R22 represents a direct bond or a linear or branched alkylene group having 2 to 6 carbon atoms, independently of each other. The alkylene group is preferably an ethylene group, a propylene group or a butylene group.

In the above-indicated general formula (I), each of Z1, Z2, Z3, Z4, Z5 and Z6 represents a direct bond or a polyoxyalkylene chain having an oxyalkylene group as a repeating unit, independently of one another. At least one of Z1 to Z6 is the polyoxyethylene chain in which the number of repetition of the oxyethylene group is two or more, and at least one of Z1 to Z6 which is not the polyoxyethylene chain is the polyoxyalkylene chain having the oxyalkylene group other than the oxyethylene group as the repeating unit. As described above, the number of repetition of the oxyethylene group in the polyoxyethylene chain is preferably within the range from 4 to 15, and more preferably within the range from 4 to 10, and the polyoxyalkylene chain having the oxyalkylene group other than the oxyethylene group as the repeating unit is preferably the polyoxypropylene chain in which the number of repetition of the oxypropylene group is within the range from 5 to 16.
In the above-indicated general formula (I), U1 is a group represented by a general formula (IV) given below, and includes the urethane bond in the molecular chain of the polysiloxane-based macromonomer.

-E21-X21—  (IV)

In the above-indicated general formula (IV), E21 represents a —NHCO— group (in this case, E21 forms the urethane bond with X21) or a divalent group derived from a diisocyanate selected from a group consisting of saturated aliphatic diisocyanates, unsaturated aliphatic diisocyanates, alicyclic diisocyanates and aromatic diisocyanates (in this case, E21 forms the urethane bond with each of Z1 and X21), and X21 represents an oxygen atom.

In the above-indicated general formula (I), U2 is a group represented by a general formula (VI) given below, and includes the urethane bond in the molecular chain of the polysiloxane-based macromonomer.

—R41—X41-E41-X42—R42—  (VI)

In the above-indicated general formula (VI), each of R41 and R42 represents a linear or branched alkylene group having 2 to 6 carbon atoms, independently of each other, and each of X41 and X42 represents an oxygen atom or an alkylene glycol group, independently of each other, while E41 represents a divalent group derived from a diisocyanate selected from the group consisting of saturated aliphatic diisocyanates, unsaturated aliphatic diisocyanates, alicyclic diisocyanates and aromatic diisocyanates (in this case, E41 forms the urethane bond with each of X41 and X42).

In the above-indicated general formula (I), U3 is a group represented by a general formula (VII) given below, and includes the urethane bond in the molecular chain of the polysiloxane-based macromonomer.

—X22-E22-  (VII)

In the above-indicated general formula (VII), X22 represents an oxygen atom, and E22 represents the —NHCO— group (in this case, E22 forms the urethane bond with X22) or a divalent group derived from a diisocyanate selected from the group consisting of saturated aliphatic diisocyanates, unsaturated aliphatic diisocyanates, alicyclic diisocyanates and aromatic diisocyanates (in this case, E22 forms the urethane bond with each of Z5 and X22).

Examples of the divalent groups which are represented by E21 in the above-indicated general formula (IV), E41 in the above-indicated general formula (VI), and E22 in the above-indicated general formula (VII), and which are derived from the diisocyanates selected from the group consisting of saturated aliphatic diisocyanates, unsaturated aliphatic diisocyanates, alicyclic diisocyanates and aromatic diisocyanates include: divalent groups derived from saturated aliphatic diisocyanates such as ethylene diisocyanate, propane-1,3-diisocyanate and hexamethylene diisocyanate; divalent groups derived from alicyclic diisocyanates such as cyclohexane-1,2-diisocyanate, bis(4-isocyanatecyclohexyl)methane and isophorone diisocyanate; divalent groups derived from aromatic diisocyanates such as tolylene diisocyanate and naphthalene-1,5-diisocyanate; and divalent groups derived from unsaturated aliphatic diisocyanates such as 2,2′-diisocyanate diethyl fumarate. Among the above-indicated divalent groups, the divalent groups respectively derived from hexamethylene diisocyanate and isophorone diisocyanate are advantageously employed in the present invention, since those divalent groups are relatively easily available and can impart a high degree of strength to the ophthalmic lens to be obtained as the end product.
In the above-indicated general formula (I), each of S1 and S2, which are independent of each other, is a group represented by a general formula (V) given below.




In the above-indicated general formula (V), each of R31 and R38 represents a linear or branched alkylene group having 2 to 6 carbon atoms, independently of each other, and each of R32, R33, R34, R35, R36 and R37 represents an alkyl group having 1 to 6 carbon atom(s), a fluorine-substituted alkyl group or a phenyl group, independently of one another.

Examples of the fluorine-substituted alkyl group described above include 3,3,3-trifluoro-n-propyl group, 2,2,2-trifluoroisopropyl group, 4,4,4-trifluoro-n-butyl group, 3,3,3-trifluoroisobutyl group, 3,3,3-trifluoro-sec-butyl group, 2,2,2-trifluoro-tert-butyl group, 5,5,5-trifluoro-n-pentyl group, 4,4,4-trifluoroisopentyl group, 3,3,3-trifluoroneopentyl group and 6,6,6-trifluorohexyl group. An anti-stain property of the ophthalmic lens against deposition of protein, lipid or the like can be effectively improved by using the polysiloxane-based macromonomer having the above-indicated fluorine-substituted alkyl group, and increasing an amount of use of the macromonomer.
In the above-indicated general formula (V), K is an integer within a range from 1 to 1500, L is 0 or an integer within the range from 1 to 1500, and a sum of K and L: “K+L” is an integer within the range from 1 to 1500. Where the value “K+L” is larger than 1500, the polysiloxane-based macromonomer has an excessively large molecular weight, whereby compatibility of the macromonomer with the other polymerizable components to be mixed with the macromonomer in the production of the ophthalmic lens is deteriorated, giving rise to a risk that the macromonomer cannot be sufficiently dissolved at the time of its mixing with the other components, or the mixture is clouded at the time of polymerization, resulting in failure to obtain a homogeneous and transparent material for the ophthalmic lens. On the other hand, the value “K+L” of 0 not only results in reduction of the oxygen permeability of the ophthalmic lens material obtained by using the macromonomer, but also results in tendency of reduction of flexibility of the ophthalmic lens material. In the polysiloxane-based macromonomer according to the invention, the value “K+L” is preferably an integer within a range from 2 to 1000, and more preferably an integer within a range from 3 to 500.
In the above-indicated general formula (I), n is 0 or an integer within a range from 1 to 10. Where the value n is larger than 10, the polysiloxane-based macromonomer has an excessively large molecular weight, whereby compatibility of the macromonomer with the other polymerizable components to be mixed with the macromonomer in the production of the ophthalmic lens is deteriorated, giving rise to the risk that the macromonomer cannot be sufficiently dissolved at the time of its mixing with the other components, or the mixture is clouded at the time of polymerization, resulting in the failure to obtain a homogeneous and transparent material for the ophthalmic lens. The value n in the above-indicated general formula (I) is more preferably 0 or an integer within a range from 1 to 5.
Preferable forms of the polysiloxane-based macromonomer used in the production of the ophthalmic lens according to the invention are represented by general formulas (VIII) and (IX) given below, for example. However, it goes without saying that the polysiloxane-based macromonomer used in the production of the ophthalmic lens according to the invention is not limited to those represented by the general formulas (VIII) and (IX).




(In the above-indicated general formula (VIII), R51 represents a hydrogen atom or a methyl group, a is an integer not smaller than two, b is an integer not smaller than two and n is an integer within a range from 1 to 1500. Further, each of R52 and R53 is a hydrogen atom or a methyl group, wherein R53 is the methyl group in the case where R52 is the hydrogen atom, and R53 is the hydrogen atom in the case where R52 is the methyl group.)





(In the above-indicated general formula (IX), a′ is an integer not smaller than two, b′ is an integer not smaller than two and n′ is an integer within a range from 1 to 1500. Further, each of R61 and R62 is a hydrogen atom or a methyl group, wherein R62 is the methyl group in the case where R61 is the hydrogen atom, and R62 is the hydrogen atom in the case where R61 is the methyl group.)

The polysiloxane-based macromonomer described above can be produced by using various known compounds as starting materials (raw materials), and successively or stepwisely reacting those compounds with each other by a conventional method.
By the way, the ophthalmic lens according to the invention is produced by using the polysiloxane-based macromonomer having the specific structure described above, as one of raw material monomers. Other components than the polysiloxane-based macromonomer to be used in the production of the ophthalmic lens can be appropriately selected from various known components depending on the type of the intended ophthalmic lens, as long as the polymer to be obtained satisfies the relationship indicated by the above-indicated formula (A). Hereinafter, the term “polysiloxane-based macromonomer” should be interpreted to mean the polysiloxane-based macromonomer having the specific structure described above.
Examples of the components used in the production of the ophthalmic lens according to the invention include the hydrophilic monomer, the hydrophobic monomer, a crosslinking agent, a reinforcing agent, a hydrophilicity agent, an ultraviolet-absorbing agent and a colorant, for example.
Specific examples of the hydrophilic monomer include: N-vinylpyrrolidone (NVP); acrylamide-based monomers such as acrylamide, N,N-dimethylacrylamide (DMAA), N,N-diethylacrylamide, N,N-dimethylaminopropylacrylamide, N-isopropylacrylamide and acryloylmorpholine; hydroxyalkyl acrylates such as 2-hydroxyethyl acrylate, hydroxypropyl acrylate and hydroxybutyl acrylate; (alkyl)aminoalkyl acrylates such as 2-dimethylaminoethyl acrylate and 2-butylaminoethyl acrylate; alkylene glycol monoacrylates such as ethylene glycol monoacrylate and propylene glycol monoacrylate; ethylene glycol allyl ether; ethylene glycol vinyl ether; acrylic acid; aminostyrene; hydroxystyrene; vinyl acetate; glycidyl acrylate; allylglycidylether; vinyl propionate; N-vinyl lactams such as N-vinyl-3-methyl-2-pyrrolidone, N-vinyl-4-methyl-2-pyrrolidone, N-vinyl-5-methyl-2-pyrrolidone, N-vinyl-6-methyl-2-pyrrolidone, N-vinyl-3-ethyl-2-pyrrolidone, N-vinyl-4,5-dimethyl-2-pyrrolidone, N-vinyl-5,5-dimethyl-2-pyrrolidone, N-vinyl-3,3,5-trimethyl-2-pyrrolidone, N-vinyl-2-piperidone, N-vinyl-3-methyl-2-piperidone, N-vinyl-4-methyl-2-piperidone, N-vinyl-5-methyl-2-piperidone, N-vinyl-6-methyl-2-piperidone, N-vinyl-6-ethyl-2-piperidone, N-vinyl-3,5-dimethyl-2-piperidone, N-vinyl-4,4-dimethyl-2-piperidone, N-vinyl-2-caprolactam, N-vinyl-3-methyl-2-caprolactam, N-vinyl-4-methyl-2-caprolactam, N-vinyl-7-methyl-2-caprolactam, N-vinyl-7-ethyl-2-caprolactam, N-vinyl-3,5-dimethyl-2-caprolactam, N-vinyl-4,6-dimethyl-2-caprolactam and N-vinyl-3,5,7-trimethyl-2-caprolactam; N-vinylamides such as N-vinylformamide, N-vinyl-N-methylformamide, N-vinyl-N-ethylformamide, N-vinylacetamide, N-vinyl-N-methylacetamide, N-vinyl-N-ethylacetamide and N-vinylphthalimide; and 1-methyl-3-methylene-2-pyrrolidinone.
As the hydrophobic monomer, it is possible to use, for example, a silicon-containing monomer and a fluorine-containing alkyl (meth)acrylate, which are conventionally used for the ophthalmic lens. These hydrophobic monomers are used as auxiliary components for the polysiloxane-based macromonomer. It is particularly noted that compatibility of the polymerizable composition can be improved by addition of the silicon-containing monomer other than the polysiloxane-based macromonomer, since the silicon-containing monomer has a lower molecular weight than the polysiloxane-based macromonomer. On the other hand, the fluorine-containing alkyl (meth)acrylate improves solubility of oxygen into the lens (polymer), which solubility is one of factors that influence the oxygen permeability of the contact lens. Further, the fluorine-containing alkyl (meth)acrylate reduces adhesiveness (tackiness) of lens surfaces, and effectively prevents adhesion of lipid or the like to the lens surfaces, owing to its hydrophobic and lipophobic properties, to improve the anti-stain property of the lens. It is to be understood that the expression “ . . . (meth)acrylate” is used in this specification as a generic expression including “ . . . acrylate” and “ . . . methacrylate”.
Examples of the silicon-containing monomer described above include generally used silicon-containing monomers such as siloxanyl (meth)acrylate and siloxanyl styrene wherein a pentamethyl disiloxymethyl group, a bis(trimethylsiloxy) (methyl)silylmethyl group, a bis(trimethylsiloxy) (methyl)silylpropyl group, a tris(trimethylsiloxy) silylmethyl group, a tris(trimethylsiloxy) silylpropyl group or the like is introduced into (meth)acrylate, styrene or the like. Among the above-indicated silicon-containing monomers, bis(trimethylsiloxy) (methyl)silylpropyl (meth)acrylate and tris(trimethylsiloxy) silylpropyl (meth)acrylate are particularly preferably used in view of ease of purification, oxygen permeability, availability, compatibility, etc.
Examples of the fluorine-containing alkyl (meth)acrylate include 2,2,2-trifluoroethyl (meth)acrylate, 2,2,3,3,3-pentafluoropropyl (meth)acrylate, (perfluorobutyl)ethyl (meth)acrylate, (perfluorohexyl)ethyl (meth)acrylate, (perfluorooctyl)ethyl (meth)acrylate, (perfluorodecyl)ethyl (meth)acrylate and (perfluorododecyl)ethyl (meth)acrylate. Among the above-indicated fluorine-containing alkyl (meth)acrylates, one having a fluorinated portion of a large molecular weight is more preferably employed, since such a fluorine-containing alkyl (meth)acrylate is suitable to achieve more excellent oxygen permeability, and gives an adequate degree of flexibility or softness to the lens. Examples of the fluorine-containing alkyl (meth)acrylate having the fluorinated portion of a large molecular weight include (perfluorohexyl)ethyl (meth)acrylate, (perfluorooctyl)ethyl (meth)acrylate and (perfluorodecyl)ethyl (meth)acrylate. Among the above-indicated fluorine-containing alkyl (meth)acrylates, (perfluorooctyl)ethyl (meth)acrylate is most preferable, since it is commercially available and can be easily purified by distillation under a reduced pressure, for example.
On the other hand, the crosslinking agent is used as necessary in order to improve the mechanical strength of the ophthalmic lens and to make the ophthalmic lens maintain its shape with a higher degree of stability, for example. The crosslinking agent is appropriately used depending on the kind of the polysiloxane-based macromonomer. For instance, in the case where the polysiloxane-based macromonomer has a multiplicity of polymerizable groups in a molecule, use of the crosslinking agent is not usually required. On the other hand, in the case where the number of the polymerizable group in the polysiloxane-based macromonomer is relatively small, and in the case where an amount of use of the above-indicated hydrophobic monomer is relatively small, there is a risk that the ophthalmic lens has problems in terms of its shape stability, strength, durability, for example, so that it is preferable to use a suitable crosslinking agent.
It is possible to use any of various known crosslinking agents which have at least two polymerizable groups and which are conventionally used in the production of the ophthalmic lens. Examples of the crosslinking agent include: (meth)acrylates of polyhydric alcohols such as ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, 1,4-butanediol, 1,6-hexanediol, trimethylol propane and pentaerythritol; divinyl adipate; diallyl adipate; allyl ester vinyl ester adipate; divinyl sebacate; diallyl sebacate; allyl ester vinyl ester sebacate; vinyl esters and allyl esters of polybasic carboxylic acids such as oxalic acid, malonic acid, maleic acid, methylmalonic acid, succinic acid, dimethylmalonic acid, ethylmalonic acid, methylsuccinic acid, glutaric acid, dimethylsuccinic acid, isopropylmalonic acid, methylglutaric acid, methyladipic acid, pimelic acid, suberic acid, di-n-propylmalonic acid, 1,9-nonanedicarboxylic acid, 1,10-decanedicarboxylic acid, 1,3-phenylenediacetic acid, phenylsuccinic acid, benzylmalonic acid, 1,2,3-propanetricarboxylic acid, 1,3,5-pentanetricarboxylic acid and 1,2,3,4-butanetetracarboxylic acid. In view of the solubility, it is more preferable that all carboxyl groups in each of the polybasic carboxylic acids described above are esterified (completely esterified). Examples of the crosslinking agent further include: divinyl benzene; triallyl cyanurate; triallyl isocyanurate; diethylene glycol bisallyl carbonate; triallyl ester of trimellitic acid; allyl ether; diallyl ether of alkylene glycol or polyalkylene glycol; divinyl ether of alkylene glycol or polyalkylene glycol; allyl ether vinyl ether of alkylene glycol or polyalkylene glycol; diallylidene pentaerythritol; 1,3,5-trivinyl-1,3,5-trimethylcyclotrisiloxane; vinyl (meth)acrylate; and allyl (meth)acrylate. At least one of the above-indicated known crosslinking agents is suitably selected and used.
The crosslinking agent is preferably used in the polymerizable composition in an amount of 0.0005-10 parts by weight per 100 parts by weight of a total amount of the monomer components (polysiloxane-based macromonomer, hydrophilic monomer and hydrophobic monomer) described above. In the case where the crosslinking agent is required and the amount of its use is excessively small, the effect of the crosslinking agent cannot be sufficiently achieved, giving rise to a risk that the ophthalmic lens which has absorbed water fails to keep its shape such as a circular shape with high stability, and to have an adequate degree of elasticity, for example. On the other hand, an excessively large amount of use of the crosslinking agent results in an excessively large number of crosslinking points in the polymer, giving rise to a risk that the ophthalmic lens becomes fragile and is easily broken.
The reinforcing agent is used for adjusting the mechanical strength of the ophthalmic lens. For instance, in the case where the polysiloxane-based macromonomer has a multiplicity of polymerizable groups in a molecule, the polysiloxane-based macromonomer itself has a crosslinking effect, so that the ophthalmic lens having excellent resilience can be obtained by using the macromonomer. However, in the case where the strength of the ophthalmic lens is lowered due to the crosslinking effect of the polysiloxane-based macromonomer, it is preferable to use the reinforcing agent.
It is possible to use any of various known reinforcing agents conventionally used for the ophthalmic lens. Specific examples of the reinforcing agent include: vinyl esters and allyl esters of organic carboxylic acids such as vinyl acetate and allyl propionate; (meth)acrylate and its macromonomer; and styrene derivatives. At least one of the above-indicated known reinforcing agents is suitably selected and used.
The reinforcing agent is preferably used in the polymerizable composition in an amount of 1-20 parts by weight per 100 parts by weight of the total amount of the monomer components (polysiloxane-based macromonomer, hydrophilic monomer and hydrophobic monomer) described above. In the case where the reinforcing agent is used in an amount less than 1 part by weight per 100 parts by weight of the monomer components, there is a risk of failure to sufficiently achieve a reinforcing effect. On the other hand, in the case where more than 20 parts by weight of the reinforcing agent is used per 100 parts by weight of the monomer components, it is difficult to achieve a desired degree of oxygen permeability of the ophthalmic lens, and there is a risk that the ophthalmic lens cannot have a sufficiently high water content.
The hydrophilicity agent is used for giving hydrophilicity to the ophthalmic lens. It is preferable to appropriately use the hydrophilicity agent in the case where the ophthalmic lens obtained by copolymerization of the polymerizable composition including the above-described monomer components has the intended water content, but the surfaces of the ophthalmic lens do not exhibit sufficiently high hydrophilicity or wettability. The hydrophilicity agent is also preferably used in each of the cases where compatibility of polymerizable monomers with respect to each other is insufficient, the ophthalmic lens has excessively high elasticity, and the polymerizable composition has extremely high affinity with respect to materials of vessels used for polymerization of the polymerizable composition and formation of the ophthalmic lens.
It is possible to use any known hydrophilicity agent conventionally used for the ophthalmic lens. Examples of the hydrophilicity agent include: mono (meth)acrylates of polyhydric alcohols such as ethylene glycol, propylene glycol and 1,6-hexane diol; N-(meth)acryloyl morpholine; N-(meth)acryloyl piperidine; N-vinyl piperidone; N-vinyl-N-methyl acetamide; N-vinyl-N-ethyl acetamide; N-vinyl-N-methyl formamide; and N-methyl-α-methylene-2-pyrrolidone. At least one of the above-indicated known hydrophilicity agents is suitably selected and used.
The hydrophilicity agent is used in the polymerizable composition in an amount of 1-30 parts by weight per 100 parts by weight of the total amount of the monomer components (polysiloxane-based macromonomer, hydrophilic monomer and hydrophobic monomer) described above. In the case where the hydrophilicity agent is required and used in an amount less than 1 part by weight per 100 parts by weight of the monomer components, there is a risk that the hydrophilicity agent cannot sufficiently exhibit its hydrophilization effect on the ophthalmic lens to be obtained as the end product. On the other hand, in the case where more than 30 parts by weight of the hydrophilicity agent is used per 100 parts by weight of the monomer components, there is a risk of deterioration of compatibility of the monomers with respect to each other, and difficulty in achieving the desired degree of oxygen permeability.
In the production of the ophthalmic lens according to the invention, it is also possible to use various other components or additives which are generally used in the production of the ophthalmic lens, as necessary, in addition to the components described above. For instance, in the case where the ophthalmic lens according to the invention is to be used as the contact lens, examples of the other components or additives which can be used in the production of the ophthalmic lens include: a polymerizable ultraviolet-absorbing agent for imparting ultraviolet absorptivity to the contact lens; a polymerizable colorant for coloring the contact lens; and a polymerizable ultraviolet-absorbing colorant for imparting the ultraviolet absorptivity to the contact lens and coloring the contact lens.
Examples of the polymerizable ultraviolet-absorbing agent include: benzophenone-based polymerizable ultraviolet-absorbing agents such as 2-hydroxy-4-(meth)acryloyloxybenzophenone, 2-hydroxy-4-(meth)acryloyloxy-5-tert-butylbenzophenone, 2-hydroxy-4-(meth)acryloyloxy-2′,4′-dichlorobenzophenone and 2-hydroxy-4-(2′-hydroxy-3′-(meth)acryloyloxypropoxy)benzophenone; benzotriazole-based polymerizable ultraviolet-absorbing agents such as 2-(2′-hydroxy-5′-(meth)acryloyloxyethylphenyl)-2H-benzotriazole [HMEPBT], 2-(2′-hydroxy-5′-(meth)acryloyloxyethylphenyl)-5-chloro-2H-benzotriazole, 2-(2′-hydroxy-5′-(meth)acryloyloxypropylphenyl)-2H-benzotriazole, 2-(2′-hydroxy-5′-(meth)acryloyloxypropyl-3′-tert-butylphenyl)-5-chloro-2H-benzotriazole and 2-(2′-hydroxy-5′-(2′′-methacryloyloxyethoxy)-3′-tert-butylphenyl)-5-methyl-2H-benzotriazole; salicylic acid derivative-based polymerizable ultraviolet-absorbing agents such as phenyl 2-hydroxy-4-(meth)acryloyloxymethylbenzoate; and methyl 2-cyano-3-phenyl-3-(3′-(meth)acryloyloxyphenyl)propenoate. The above-indicated polymerizable ultraviolet-absorbing agents may be used alone or in combination as a mixture of two or more of them.
Examples of the polymerizable colorant include azo-based polymerizable colorants such as 1-phenylazo-4-(meth)acryloyloxynaphthalene, 1-phenylazo-2-hydroxy-3-(meth)acryloyloxynaphthalene, 1-naphthylazo-2-hydroxy-3-(meth)acryloyloxynaphthalene, 1-(α-anthrylazo)-2-hydroxy-3-(meth)acryloyloxynaphthalene, 1-((4′-(phenylazo)-phenyl)azo)-2-hydroxy-3-(meth)acryloyloxynaphthalene, 1-(2′,4′-xylylazo)-2-(meth)acryloyloxynaphthalene, 1-(o-tolylazo)-2-(meth)acryloyloxynaphthalene, 2-(m-(meth)acryloylamide-anilino)-4,6-bis(1′-(o-tolylazo)-2′-naphthylamino)-1,3,5-triazin e, 2-(m-vinylanilino)-4-((4′-nitrophenylazo)-anilino)-6-chloro-1,3,5-triazine, 2-(1′-(o-tolylazo)-2′-naphthyloxy)-4-(m-vinylanilino)-6-chloro-1,3,5-triazine, 2-(p-vinylanilino)-4-(1′-(o-tolylazo)-2′-naphthylamino)-6-chloro-1,3,5-triazine, N-(1′-(o-tolylazo)-2′-naphthyl)-3-vinylphthalic acid monoamide, N-(1′-(o-tolylazo)-2′-naphthyl)-6-vinylphthalic acid monoamide, 3-vinylphthalic acid-(4′-(p-sulfophenylazo)-1′-naphthyl)monoester, 6-vinylphthalic acid-(4′-(p-sulfophenylazo)-1′-naphthyl)monoester, 3-(meth) acryloylamide-4-phenylazophenol, 3-(meth)acryloylamide-4-(8′-hydroxy-3′,6′-disulfo-1′-naphthylazo)phenol, 3-(meth)acryloylamide-4-(1′-phenylazo-2′-naphthylazo)phenol, 3-(meth)acryloylamide-4-(p-tolylazo)phenol, 2-amino-4-(m-(2′-hydroxy-1′-naphthylazo)anilino)-6-isopropenyl-1,3,5-triazine, 2-amino-4-(N-methyl-p-(2′-hydroxy-t-naphthylazo)anilino)-6-isopropenyl-1, 3,5-triazine, 2-amino-4-(m-(4′-hydroxy-1′-phenylazo)anilino)-6-isopropenyl-1,3,5-triazine, 2-amino-4-(N-methyl-p-(4′-hydroxyphenylazo)anilino)-6-isopropenyl-1,3,5-triazine, 2-amino-4-(m-(3′-methyl-1′-phenyl-5′-hydroxy-4′-pyrazolylazo)anilino)-6-isopropenyl-1,3,5-triazine, 2-amino-4-(N-methyl-p-(3′-methyl-1′-phenyl-5′-hydroxy-4′-pyrazolylazo)anilino)-6-isopropenyl-1,3,5-triazine, 2-amino-4-(p-phenylazoanilino)-6-isopropenyl-1,3,5-triazine and 4-phenylazo-7-(meth)acryloylamide-1-naphthol.
Further examples of the polymerizable colorant include: anthraquinone-based polymerizable colorants such as 1,5-bis((meth)acryloylamino)-9,10-anthraquinone, 1-(4′-vinylbenzoylamide)-9,10-anthraquinone, 4-amino-1-(4′-vinylbenzoylamide)-9,10-anthraquinone, 5-amino-1-(4′-vinylbenzoylamide)-9,10-anthraquinone, 8-amino-1-(4′-vinylbenzoylamide)-9,10-anthraquinone, 4-nitro-1-(4′-vinylbenzoylamide)-9,10-anthraquinone, 4-hydroxy-1-(4′-vinylbenzoylamide)-9,10-anthraquinone, 1-(3′-vinylbenzoylamide)-9,10-anthraquinone, 1-(2′-vinylbenzoylamide)-9,10-anthraquinone, 1-(4′-isopropenylbenzoylamide)-9,10-anthraquinone, 1-(3′-isopropenylbenzoylamide)-9,10-anthraquinone, 1-(2′-isopropenylbenzoylamide)-9,10-anthraquinone, 1,4-bis-(4′-vinylbenzoylamide)-9,10-anthraquinone, 1,4-bis-(4′-isopropenylbenzoylamide)-9,10-anthraquinone, 1,5′-bis-(4′-vinylbenzoylamide)-9,10-anthraquinone, 1,5-bis-(4′-isopropenylbenzoylamide)-9,10-anthraquinone, 1-methylamino-4-(3′-vinylbenzoylamide)-9,10-anthraquinone, 1-methylamino-4-(4′-vinylbenzoyloxyethylamino)-9,10-anthraquinone, 1-amino-4-(3′-vinylphenylamino)-9,10-anthraquinone-2-sulfonic acid, 1-amino-4-(4′-vinylphenylamino)-9,10-anthraquinone-2-sulfonic acid, 1-amino-4-(2′-vinylbenzylamino)-9,10-anthraquinone-2-sulfonic acid, 1-amino-4-(3′-(meth)acryloylaminophenylamino)-9,10-anthraquinone-2-sulfonic acid, 1-amino-4-(3′-(meth)acryloylaminobenzylamino)-9,10-anthraquinone-2-sulfonic acid, 1-(β-ethoxycarbonylallylamino)-9,10-anthraquinone, 1-(β-carboxyallylamino)-9,10-anthraquinone, 1,5-di-(β-carboxyallylamino)-9,10-anthraquinone, 1-(β-isopropoxycarbonylallylamino)-5-benzoylamide-9,10-anthraquinone, 2-(3′-(meth)acryloylamide-anilino)-4-(3′-(3′′-sulfo-4′′-aminoanthraquinone-1′′-yl)amino-anilino)-6-chloro-1,3,5-triazine, 2-(3′-(meth)acryloylamide-anilino)-4-(3′-(3′′-sulfo-4′′-aminoanthraquinone-1′′-yl)amino-anilino)-6-hydrazino-1,3,5-triazine, 2,4-bis-((4′′-methoxyanthraquinone-1′′-yl)amino)-6-(3′-vinylanilino)-1,3,5-triazine and 2-(2′-vinylphenoxy)-4-(4′-(3′′-sulfo-4′′-aminoanthraquinone-1′′-yl-amino)anilino)-6-chloro-1,3,5-triazine; nitro-based polymerizable colorants such as o-nitroanilinomethyl (meth)acrylate; and phthalocyanine-based polymerizable colorants such as (meth)acryloyl-modified tetraamino copper phthalocyanine and (meth)acryloyl-modified (dodecanoyl-modified tetraamino copper phthalocyanine). The above-indicated polymerizable colorants may be used alone or in combination as a mixture of two or more of them.
Examples of the polymerizable ultraviolet-absorbing colorant include benzophenone-based polymerizable ultraviolet-absorbing colorants such as 2,4-dihydroxy-3-(p-styrenoazo)benzophenone, 2,4-dihydroxy-5-(p-styrenoazo)benzophenone, 2,4-dihydroxy-3-(p-(meth)acryloyloxymethylphenylazo)benzophenone, 2,4-dihydroxy-5-(p-(meth)acryloyloxymethylphenylazo)benzophenone, 2,4-dihydroxy-3-(p-(meth)acryloyloxyethylphenylazo)benzophenone, 2,4-dihydroxy-5-(p-(meth)acryloyloxyethylphenylazo)benzophenone, 2,4-dihydroxy-3-(p-(meth)acryloyloxypropylphenylazo)benzophenone, 2,4-dihydroxy-5-(p-(meth)acryloyloxypropylphenylazo)benzophenone, 2,4-dihydroxy-3-(o-(meth)acryloyloxymethylphenylazo)benzophenone, 2,4-dihydroxy-5-(o-(meth)acryloyloxymethylphenylazo)benzophenone, 2,4-dihydroxy-3-(o-(meth)acryloyloxyethylphenylazo)benzophenone, 2,4-dihydroxy-5-(o-(meth)acryloyloxyethylphenylazo)benzophenone, 2,4-dihydroxy-3-(o-(meth)acryloyloxypropylphenylazo)benzophenone, 2,4-dihydroxy-5-(o-(meth)acryloyloxypropylphenylazo)benzophenone, 2,4-dihydroxy-3-(p-(N,N-di(meth)acryloyloxyethylamino)phenylazo)benzophenone, 2,4-dihydroxy-5-(p-(N,N-di(meth)acryloyloxyethylamino)phenylazo)benzophenone, 2,4-dihydroxy-3-(o-(N,N-di(meth)acryloyloxyethylamino)phenylazo)benzophenone, 2,4-dihydroxy-5-(o-(N,N-di(meth)acryloylethylamino)phenylazo)benzophenone, 2,4-dihydroxy-3-(p-(N-ethyl-N-(meth)acryloyloxyethylamino)phenylazo)benzophenone, 2,4-dihydroxy-5-(p-(N-ethyl-N-(meth)acryloyloxyethylamino)phenylazo)benzophenone, 2,4-dihydroxy-3-(o-(N-ethyl-N-(meth)acryloyloxyethylamino)phenylazo)benzophenone, 2,4-dihydroxy-5-(o-(N-ethyl-N-(meth)acryloyloxyethylamino)phenylazo)benzophenone, 2,4-dihydroxy-3-(p-(N-ethyl-N-(meth)acryloylamino)phenylazo)benzophenone, 2,4-dihydroxy-5-(p-(N-ethyl-N-(meth)acryloylamino)phenylazo)benzophenone, 2,4-dihydroxy-3-(o-(N-ethyl-N-(meth)acryloylamino)phenylazo)benzophenone, 2,4-dihydroxy-5-(o-(N-ethyl-N-(meth)acryloylamino)phenylazo)benzophenone and 2,4-dihydroxy-5-(4-(2-(N-(2-methacryloyloxyethyl)carbamoyloxy)ethyl)phenylazo)benzo phenone; and benzoic acid-based polymerizable ultraviolet-absorbing colorants such as phenyl 2-hydroxy-4-(p-styrenoazo)benzoate. The above-indicated polymerizable ultraviolet-absorbing colorants may be used alone or in combination as a mixture of two or more of them.
The polymerizable ultraviolet-absorbing agent, the polymerizable colorant and the polymerizable ultraviolet-absorbing colorant are used in the polymerizable composition preferably in an amount not more than 3 parts by weight, and more preferably in an amount of 0.01-2 parts by weight, per 100 parts by weight of the total amount of the monomer components (polysiloxane-based macromonomer, hydrophilic monomer and hydrophobic monomer) described above. In the case where more than 3 parts by weight of the polymerizable ultraviolet-absorbing agent and the like are used per 100 parts by weight of the monomer components, the mechanical strength of the contact lens to be obtained tends to be deteriorated, for example. Further, a smaller amount of use of the polymerizable ultraviolet-absorbing agent and the like is preferred taking account of tonicity of the ultraviolet-absorbing agent and the colorant.
In production of a water-absorptive contact lens as a kind of the ophthalmic lens according to the invention by using the components described above, proportions of the respective components in the polymerizable composition are preferably determined such that the water content of the contact lens to be obtained as the end product is held within a range of 10-60%. In the case where the water content of the contact lens is less than 10%, the contact lens is pressed onto a cornea upon blinking of the eye, even in the presence of a tear fluid layer between the lens and the cornea, resulting in a decrease of a space between the lens and the cornea, and giving rise to a risk that the lens finally adheres or sticks to the cornea, like a sucker. On the other hand, in the case where the water content of the contact lens is more than 60%, there is a risk of reduction of the oxygen permeability. The proportions of the respective components in the polymerizable composition are particularly preferably determined such that the water content of the contact lens is held within a range of 12-55%.
The water content of the contact lens described in this specification is calculated as follows. Namely, after immersing the contact lens in water at 20° C. for two hours, the water remaining on the lens surfaces is wiped off with hygroscopic paper, and the weight (W1) of the lens in its hydrated state is measured. Then, the contact lens is dried by leaving it in a drier at 60° C. for 24 hours, and the weight (W2) of the thus dried contact lens is measured. By using the weight:W1 of the lens in its hydrated state and the weight: W2 of the lens in its dry state, the water content of the lens is calculated according to the following formula:

Water content (wt %)=[(W1−W2)/W1]×100

In the production of the ophthalmic lens according to the invention, the polymerizable composition including the components appropriately selected from those described above depending on the type of the intended ophthalmic lens is prepared. Then, the intended ophthalmic lens is obtained by copolymerizing the thus prepared polymerizable composition by one of various known polymerization methods. For instance, the water-absorptive contact lens can be produced by methods described below.
Examples of the polymerization method for polymerizing the polymerizable composition in the production of the water-absorptive contact lens include: a method (heat polymerization method) in which a heat polymerization initiator is added to the polymerizable composition, and then the polymerizable composition is gradually or stepwisely heated within a range from the room temperature to about 150° C. for polymerization; a method (photopolymerization method) in which a photopolymerization initiator (and photosensitizer) is added to the polymerizable composition, and then the polymerizable composition is irradiated with a suitable ray of light (ultraviolet ray, electron beam or the like) for polymerization; and a combination of the heat polymerization method and the photopolymerization method. The polymerization may be conducted by a bulk polymerization process, a solution polymerization process or any other known polymerization process.
A method of forming (processing) the contact lens is not particularly limited. It is possible to employ any of various conventional methods known to those skilled in the art, such as: a mechanical processing method in which the polymerizable composition is accommodated and polymerized in a suitable polymerization mold or polymerization vessel, to obtain a contact lens material (ophthalmic lens material) in the form of a bar, a block, a plate or the like, which is formed of the polymer of the polymerizable composition, and then the contact lens material is formed into a desired shape by a machining process such as cutting, grinding or the like; a cast molding method (molding method) in which a predetermined polymerizable monomer composition is accommodated in a molding cavity of a polymerization mold which gives the shape of the intended contact lens, and a formed article is obtained by polymerizing the above-described polymerizable components within the polymerization mold; and a combination of the molding method and the mechanical processing method, in which a mechanical finishing process is performed as necessary. Among the above-described methods, the molding method is particularly preferably used to effectively reduce the cost of production of the lens.
Examples of the heat polymerization initiator which is used in the case where the polymerizable composition is polymerized by the heat polymerization method include 2,2′-azobisisobutyronitrile, 2,2′-azobis(2,4-dimethylvaleronitrile), benzoylperoxide, tert-butyl hydroperoxide, cumene hydroperoxide, lauroyl peroxide, tert-butylperoxy hexanoate and 3,5,5-trimethylhexanoylperoxide. The above-indicated heat polymerization initiators may be used alone or in combination as a mixture of two or more of them. The heat polymerization initiator is used preferably in an amount of 0.001-2 parts by weight, and more preferably in an amount of 0.01-1 part by weight, per 100 parts by weight of the total amount of the monomer components in the polymerizable composition described above.
In the heat polymerization method, the polymerizable composition is heated to a temperature preferably within a range of 50-150° C., and more preferably within a range of 60-140° C., for a time period of preferably 10-120 min, and more preferably 20-60 min. It is possible to reduce a required time for the polymerization by heating the polymerizable composition to a temperature not lower than 50° C. It is possible to reduce an amount of residual monomer components by heating the polymerizable composition for not shorter than 10 min. On the other hand, volatilization of the monomer components can be effectively restricted by heating the polymerizable composition to a temperature not higher than 150° C., for not longer than 120 min.
Examples of the photopolymerization initiator which is used in the case where the polymerizable composition is polymerized by the photopolymerization method include: phosphine oxide-based photopolymerization initiators such as 2,4,6-trimethylbenzoyl-diphenylphosphine oxide (TPO) and bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide; benzoin-based photopolymerization initiators such as methyl orthobenzoylbenzoate, methyl benzoylformate, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin isobutyl ether and benzoin n-butyl ether; phenone-based photopolymerization initiators such as 2-hydroxy-2-methyl-1-phenylpropane-1-one (HMPPO), p-isopropyl-α-hydroxyisobutylphenone, p-tert-butyltrichloroacetophenone, 2,2-dimethoxy-2-phenylacetophenone, α-α-dichloro-4-phenoxyacetophenone and N,N-tetraethyl-4,4-diaminobenzophenone; 1-hydroxycyclohexyl phenyl ketone; 1-phenyl-1,2-propanedione-2-(o-ethoxycarbonyl)oxime; thioxanthone-based photopolymerization initiators such as 2-chlorothioxanthone and 2-methylthioxanthone; dibenzosuberone; 2-ethylanthraquinone; benzophenone acrylate; benzophenone; and benzil. The above-indicated photopolymerization initiators may be used alone or in combination as a mixture of two or more of them. Further, the photosensitizer may be used together with the photopolymerization initiator. The photopolymerization initiator and the photosensitizer are used preferably in an amount of 0.001-2 parts by weight, and more preferably in an amount of 0.01-1 part by weight, per 100 parts by weight of the total amount of the monomer components in the polymerizable composition described above.
In the case of polymerizing the polymerizable composition by the photopolymerization method, it is necessary to select the photopolymerization initiator to be used, depending on a range of the wavelength of the light with which the polymerizable composition is to be irradiated. An illumination intensity of the light is preferably set within a range of 0.1-100 mW/cm2. The photopolymerization method may be conducted by stepwisely irradiating the polymerizable composition with lights having respective different illumination intensities. The polymerizable composition is preferably irradiated with the light for a time period not shorter than 1 min. By setting the illumination intensity and the irradiation time as described above, it is possible to sufficiently cure the polymerizable composition, while preventing deterioration of the material of the casting mold (or the polymerization vessel). It is also possible to heat the polymerizable composition simultaneously with its irradiation with the light, whereby the polymerization reaction is promoted, and a copolymer can be easily formed. Although the material of the casting mold or the polymerization vessel is not particularly limited, as long as the light required for the polymerization (curing) of the polymerizable composition can be transmitted through the material, the material is preferably selected from general-purpose resins such as polypropylene, polystyrene, nylon and polyester, for example.
The thus obtained copolymer is usually subjected to a treatment for removing residues within the copolymer. For instance, in the bulk polymerization process, a viscosity of the system increases along with progress of the polymerization reaction, so that the monomer components cannot be dispersed within the system having a high viscosity, and the monomers which cannot be involved in the polymerization reaction and which are not polymerized often remain within the copolymer. On the other hand, in the solution polymerization process, a solvent which is not involved in the polymerization reaction often remains within the copolymer. Amounts of those residues within the contact lens, which is medical equipment, should be reduced as far as possible. Specifically, the residues are eluted from the copolymer by immersing the copolymer in water, an organic solvent or a mixture thereof, and preferably by repeating such an immersing operation. As the solvent used in the above-described treatment, it is also possible to use an aqueous solution such as an isotonic sodium chloride solution in which an inorganic compound is dissolved, and a mixed solution of such an aqueous solution and an organic solvent.
The copolymer subjected to the treatment for removing the residues is then subjected to a hydration treatment in which the copolymer is immersed in water, whereby the intended water-absorptive contact lens is obtained. It goes without saying that a sterilizing treatment or the like is appropriately performed on the thus obtained contact lens, so that a sufficiently high degree of safety of the contact lens with respect to a living body is secured.
Further, after formation of the contact lens by the above-described molding method, mechanical processing method or the like, various treatments for improving surface properties of the contact lens are performed on the contact lens in the dry state or the hydrated state, as necessary. Examples of the treatments for improving the surfaces properties of the contact lens include a low-temperature plasma treatment, an atmospheric-pressure plasma treatment, a corona discharge treatment or the like. For instance, by performing the low-temperature plasma treatment, it is possible to obtain the contact lens exhibiting more excellent wettability and/or anti-stain property. Specifically, the low-temperature plasma treatment can be performed in an atmosphere of a rarefied gas of alkane having 1 to 6 carbon atom(s), fluorine-substituted alkane having 1 to 6 carbon atom(s), nitrogen, oxygen, carbon dioxide, argon, hydrogen, air, water, silane or a mixture thereof. It is particularly preferable to perform the low-temperature plasma treatment in the rarefied gas atmosphere of oxygen alone, carbon dioxide alone, or a mixture of oxygen and water, tetrafluoromethane, an organic silane, methane, nitrogen or the like, since it is expected that the low-temperature plasma treatment performed in such an atmosphere gives a physical surface-modification effect by ion etching and a chemical surface-modification effect by ion implantation of radicals. The low-temperature plasma treatment can be performed under either of a reduced pressure and the atmospheric pressure. In the low-temperature plasma treatment, it is possible to control the surface-modification effects by appropriately adjusting output, a treatment time and a gas concentration, by using a high radio frequency (e.g. 13.65 MHz), a low audio frequency (e.g. 15.0-40.0 KHz) or a microwave (e.g. 2.45 GHz). In addition, it is also effective to perform a surface treatment using an ultraviolet ray, an eximer laser, an electron beam or the like, or to perform a surface-coating treatment using a hydrophilic agent such as 2-hydroxyethyl (meth)acrylate, (meth)acrylic acid, methoxytriethylene glycol (meth)acrylate, dimethyl acrylamide or the like, in order to make the surfaces of the contact lens hydrophilic and exhibit more excellent wettability.
EXAMPLES
To clarify the invention more specifically, some examples of the invention will be described. However, it goes without saying that the invention is by no means limited to the details of the illustrated examples. Further, it is to be understood that the invention may be embodied with various changes, modifications and improvements, which are not illustrated herein and which may occur to those skilled in the art, without departing from the spirit of the invention.
Abbreviations used in the illustrated examples indicate respective compounds described below.
TRIS: 3-[tris(trimethylsiloxy)silyl]propyl methacrylate
DMAA: dimethyl acrylamide
N-MMP: 1-methyl-3-methylene-2-pyrrolidinone
TPO: diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide
HMEPBT: 2-(2′-hydroxy-5′-(meth)acryloyloxyethylphenyl)-2H-benzotriazol
HMPPO: 2-hydroxy-2-methyl-1-phenylpropane-1-one
EDMA: ethyleneglycol dimethacrylate
MTA: 2-methoxyethyl acrylate
AMA: allyl methacrylate
Initially, 15 kinds of polysiloxane-based macromonomer (macromonomers A through K and comparative macromonomers a through d) were synthesized by respective methods described below.
—Synthesis of Macromonomer A—
A 500 mL eggplant flask was charged with 107.48 g (95.96 mmol based on a functional group equivalent weight of 1120 g/mol) of a silicone which is modified with polypropylene oxide at both of its terminals, and available from Shin-Etsu Chemical Co., Ltd., JAPAN (Trade Name: X-22-4952; a number of repetition of an oxypropylene group is 10; a number of repetition of dimethylsiloxane is 20), and 26.64 g (119.85 mmol) of isophorone diisocyanate. The contents in the flask were stirred at the room temperature by using a stirrer, to dissolve the X-22-4952 in isophorone diisocyanate. Then, a solution obtained by dissolving 0.1427 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 1.8248 g of acetonitrile was added to the contents in the flask, and the contents were stirred at the room temperature for 30 minutes. Further, 26.78 g (23.91 mmol based on the functional group equivalent weight of 1120 g/mol) of the X-22-4952 was added to the contents in the flask, a Dimroth condenser was attached to the flask, and the contents in the flask were stirred at 70° C. for 2 hours in an oil bath.
A solution obtained by dissolving 0.4265 g of p-methoxyphenol (MEHQ), 86.29 g (239.69 mmol) of polyethylene glycol monomethacrylate (average molecular weight: 360) and 0.1413 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 1.8882 g of acetonitrile was added to the contents in the flask, and the contents were stirred at 70° C. for about 3 hours. A small amount of the thus obtained reaction solution was collected from the flask, and measured of an infrared absorption spectrum, whereby it was confirmed that a peak at 2350 cm−1 corresponding to a NCO group was disappeared.
The reaction solution was dissolved in 800 mL of acetonitrile, and transferred into a separating funnel. Then, 800 mL of hexane was added to the reaction solution in the separating funnel to separate the reaction solution into layers. Among three layers of the thus separated reaction solution, the lowermost layer was discarded. Further, 200 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among three layers of the thus separated reaction solution, the lowermost layer was discarded. Further, 200 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among three layers of the thus separated reaction solution, the lowermost layer was discarded. Remaining layers of the reaction solution were collected, and 0.0117 g of 4-methoxy-1-naphthol (MNT) was added to the reaction solution. By distilling solvents away from the reaction solution under a reduced pressure, 103.55 g of a polysiloxane-based macromonomer (macromonomer A) in the form of a pale yellow liquid having a high viscosity was obtained. The macromonomer A has a structure represented by the above-indicated general formula (VIII), wherein R51 is CH3— (methyl group), a is 6, b is 10 and n is 19, and an HLB value of the macromonomer A calculated according to the above-indicated formula is 2.72.
—Synthesis of Macromonomer B—
A 500 mL eggplant flask was charged with 88.30 g (90.66 mmol based on a functional group equivalent weight of 974 g/mol) of a silicone which is modified with polypropylene oxide at both of its terminals (a number of repetition of an oxypropylene group is 5; a number of repetition of dimethylsiloxane is 20), and 50.37 g (226.61 mmol) of isophorone diisocyanate. The contents in the flask were stirred at the room temperature by using a stirrer, to dissolve the silicone in isophorone diisocyanate. Then, a solution obtained by dissolving 0.1750 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 2.1474 g of acetonitrile was added to the contents in the flask, a Dimroth condenser was attached to the flask, and the contents in the flask were stirred at 70° C. for 1.5 hours in an oil bath.
A solution obtained by dissolving 0.8220 g of p-methoxyphenol (MEHQ), 163.28 g (453.56 mmol) of polyethylene glycol monomethacrylate (average molecular weight: 360) and 0.0886 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 1.5612 g of acetonitrile was added to the contents in the flask, and the contents were stirred at 70° C. for 3 hours. A small amount of the thus obtained reaction solution was collected from the flask, and measured of an infrared absorption spectrum, whereby it was confirmed that a peak at 2350 cm−1 corresponding to a NCO group was disappeared.
The reaction solution was dissolved in 600 mL of acetonitrile, and transferred into a separating funnel. Then, 600 mL of hexane was added to the reaction solution in the separating funnel to separate the reaction solution into layers. Among three layers of the thus separated reaction solution, the lowermost layer was discarded. Further, 300 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among three layers of the thus separated reaction solution, the lowermost layer was discarded. Further, 150 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among three layers of the thus separated reaction solution, the lowermost layer was discarded. Remaining layers of the reaction solution were collected, and 0.0093 g of 4-methoxy-1-naphthol (MNT) was added to the reaction solution. By distilling solvents away from the reaction solution under a reduced pressure, 67.67 g of a polysiloxane-based macromonomer (macromonomer B) in the form of a pale yellow liquid having a high viscosity was obtained. The macromonomer B has a structure represented by the above-indicated general formula (VIII), wherein R51 is CH3— (methyl group), a is 6, b is 5 and n is 19, and an HLB value of the macromonomer B calculated according to the above-indicated formula is 3.19.
—Synthesis of Macromonomer C—
A 500 mL eggplant flask was charged with 163.39 g (120.58 mmol based on a functional group equivalent weight of 1355 g/mol) of a silicone which is modified with polypropylene oxide at both of its terminals (a number of repetition of an oxypropylene group is 16; a number of repetition of dimethylsiloxane is 20), and 67.01 g (301.47 mmol) of isophorone diisocyanate. The contents in the flask were stirred at the room temperature by using a stirrer, to dissolve the silicone in isophorone diisocyanate. Then, a solution obtained by dissolving 0.3147 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 3.1922 g of acetonitrile was added to the contents in the flask, a Dimroth condenser was attached to the flask, and the contents in the flask were stirred at 70° C. for 1.5 hours in an oil bath.
A solution obtained by dissolving 1.09 g of p-methoxyphenol (MEHQ), 218.70 g (607.5 mmol) of polyethylene glycol monomethacrylate (average molecular weight: 360) and 0.1043 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 1.5178 g of acetonitrile was added to the contents in the flask, and the contents were stirred at 70° C. for 2 hours. A small amount of the thus obtained reaction solution was collected from the flask, and measured of an infrared absorption spectrum, whereby it was confirmed that a peak at 2350 cm−1 corresponding to a NCO group was disappeared.
The reaction solution was dissolved in 800 mL of acetonitrile, and transferred into a separating funnel. Then, 800 mL of hexane was added to the reaction solution in the separating funnel to separate the reaction solution into layers. Among three layers of the thus separated reaction solution, the lowermost layer was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among three layers of the thus separated reaction solution, the lowermost layer was discarded. Further, 200 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among three layers of the thus separated reaction solution, the lowermost layer was discarded. Remaining layers of the reaction solution were collected, and 0.0122 g of 4-methoxy-1-naphthol (MNT) was added to the reaction solution. By distilling solvents away from the reaction solution under a reduced pressure, 67.67 g of a pale yellow liquid having a high viscosity was obtained.
An SEC (size exclusion chromatography) analysis was conducted on the thus obtained pale yellow liquid, whereby a peak which is considered to correspond to a reaction reagent or a byproduct was observed after a peak of a macromonomer. Therefore, the liquid was separated into layers again by using 600 mL of hexane and 600 mL of acetonitrile. As a result, the lowermost layer of the thus separated liquid was constituted by a layer (which is pale yellow and which has a high viscosity) which had been located in the middle of the three layers in the previously performed separating operations. The uppermost layer was constituted by hexane. Accordingly, the intermediate layer was constituted by acetonitrile.
After discarding the layer of acetonitrile, 400 mL of acetonitrile was added to the above-described liquid to separate the liquid into layers again. By collecting the lowermost layer of the thus separated liquid, and distilling solvents away from the liquid under a reduced pressure, 76.76 g of a polysiloxane-based macromonomer (macromonomer C) in the form of a pale yellow liquid having a high viscosity was obtained. The macromonomer C has a structure represented by the above-indicated general formula (VIII), wherein R51 is CH3— (methyl group), a is 6, b is 16 and n is 19, and an HLB value of the macromonomer C calculated according to the above-indicated formula is 2.30.
—Synthesis of Macromonomer D—
A 500 mL eggplant flask was charged with 152.56 g (80.08 mmol based on a functional group equivalent weight of 1905 g/mol) of a silicone which is modified with polypropylene oxide at both of its terminals (a number of repetition of an oxypropylene group is 16; a number of repetition of dimethylsiloxane is 40), and 44.53 g (200.33 mmol) of isophorone diisocyanate. The contents in the flask were stirred at the room temperature by using a stirrer, to dissolve the silicone in isophorone diisocyanate. Then, a solution obtained by dissolving 0.2989 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 3.1234 g of acetonitrile was added to the contents in the flask, a Dimroth condenser was attached to the flask, and the contents in the flask were stirred at 70° C. for 1.5 hours in an oil bath.
A solution obtained by dissolving 0.72 g of p-methoxyphenol (MEHQ), 144.26 g (400.72 mmol) of polyethylene glycol monomethacrylate (average molecular weight: 360) and 0.1059 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 1.7584 g of acetonitrile was added to the contents in the flask, and the contents were stirred at 70° C. for 1.5 hours. A small amount of the thus obtained reaction solution was collected from the flask, and measured of an infrared absorption spectrum, whereby it was confirmed that a peak at 2350 cm−1 corresponding to a NCO group was disappeared.
The reaction solution was dissolved in 1000 mL of acetonitrile, and transferred into a separating funnel. Then, 1000 mL of hexane was added to the reaction solution in the separating funnel to separate the reaction solution into layers. Among two layers of the thus separated reaction solution, a lower layer (layer of acetonitrile) was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. A remaining layer of the reaction solution was collected, and 0.0120 g of 4-methoxy-1-naphthol (MNT) was added to the reaction solution. By distilling solvents away from the reaction solution under a reduced pressure, 100.24 g of a polysiloxane-based macromonomer (macromonomer D) in the form of a liquid having a high viscosity was obtained. The macromonomer D has a structure represented by the above-indicated general formula (VIII), wherein R51 is CH3— (methyl group), a is 6, b is 16 and n is 39, and an HLB value of the macromonomer D calculated according to the above-indicated formula is 1.74.
—Synthesis of Macromonomer E—
A 500 mL eggplant flask was charged with 112.30 g (73.78 mmol based on a functional group equivalent weight of 1522 g/mol) of a silicone which is modified with polypropylene oxide at both of its terminals (a number of repetition of an oxypropylene group is 5; a number of repetition of dimethylsiloxane is 40), and 41.01 g (184.50 mmol) of isophorone diisocyanate. The contents in the flask were stirred at the room temperature by using a stirrer, to dissolve the silicone in isophorone diisocyanate. Then, a solution obtained by dissolving 0.2009 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 1.9901 g of acetonitrile was added to the contents in the flask, a Dimroth condenser was attached to the flask, and the contents in the flask were stirred at 70° C. for 1.5 hours in an oil bath.
A solution obtained by dissolving 0.67 g of p-methoxyphenol (MEHQ), 132.76 g (368.78 mmol) of polyethylene glycol monomethacrylate (average molecular weight: 360) and 0.1013 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 1.4989 g of acetonitrile was added to the contents in the flask, and the contents were stirred at 70° C. for 3 hours. A small amount of the thus obtained reaction solution was collected from the flask, and measured of an infrared absorption spectrum, whereby it was confirmed that a peak at 2350 cm−1 corresponding to a NCO group was disappeared.
The reaction solution was dissolved in 800 mL of acetonitrile, and transferred into a separating funnel. Then, 800 mL of hexane was added to the reaction solution in the separating funnel to separate the reaction solution into layers. Among two layers of the thus separated reaction solution, a lower layer (layer of acetonitrile) was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. A remaining layer of the reaction solution was collected, and 0.0120 g of 4-methoxy-1-naphthol (MNT) was added to the reaction solution. By distilling solvents away from the reaction solution under a reduced pressure, 110.44 g of a polysiloxane-based macromonomer (macromonomer E) in the form of a liquid having a high viscosity was obtained. The macromonomer E has a structure represented by the above-indicated general formula (VIII), wherein R51 is CH3— (methyl group), a is 6, b is 5 and n is 39, and an HLB value of the macromonomer E calculated according to the above-indicated formula is 2.21.
—Synthesis of Macromonomer F—
A 500 mL eggplant flask was charged with 115.53 g (67.52 mmol based on a functional group equivalent weight of 1711 g/mol) of a silicone which is modified with polypropylene oxide at both of its terminals (a number of repetition of an oxypropylene group is 10; a number of repetition of dimethylsiloxane is 40), and 37.52 g (168.80 mmol) of isophorone diisocyanate. The contents in the flask were stirred at the room temperature by using a stirrer, to dissolve the silicone in isophorone diisocyanate. Then, a solution obtained by dissolving 0.2035 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 2.5868 g of acetonitrile was added to the contents in the flask, a Dimroth condenser was attached to the flask, and the contents in the flask were stirred at 70° C. for 1.5 hours in an oil bath.
A solution obtained by dissolving 0.61 g of p-methoxyphenol (MEHQ), 121.27 g (336.86 mmol) of polyethylene glycol monomethacrylate (average molecular weight: 360) and 0.1089 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 1.7292 g of acetonitrile was added to the contents in the flask, and the contents were stirred at 70° C. for about 1 hour. A small amount of the thus obtained reaction solution was collected from the flask, and measured of an infrared absorption spectrum, whereby it was confirmed that a peak at 2350 cm−1 corresponding to a NCO group was disappeared.
The reaction solution was dissolved in 800 mL of acetonitrile, and transferred into a separating funnel. Then, 800 mL of hexane was added to the reaction solution in the separating funnel to separate the reaction solution into layers. Among two layers of the thus separated reaction solution, a lower layer (layer of acetonitrile) was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. A remaining layer of the reaction solution was collected, and 0.0114 g of 4-methoxy-1-naphthol (MNT) was added to the reaction solution. By distilling solvents away from the reaction solution under a reduced pressure, 105.13 g of a polysiloxane-based macromonomer (macromonomer F) in the form of a liquid having a high viscosity was obtained. The macromonomer F has a structure represented by the above-indicated general formula (VIII), wherein R51 is CH3— (methyl group), a is 6, b is 10 and n is 39, and an HLB value of the macromonomer F calculated according to the above-indicated formula is 1.97.
—Synthesis of Macromonomer G—
A 500 mL eggplant flask was charged with 121.95 g (54.03 mmol based on a functional group equivalent weight of 2257 g/mol) of a silicone which is modified with polypropylene oxide at both of its terminals (a number of repetition of an oxypropylene group is 10; a number of repetition of dimethylsiloxane is 60), and 30.10 g (135.41 mmol) of isophorone diisocyanate. The contents in the flask were stirred at the room temperature by using a stirrer, to dissolve the silicone in isophorone diisocyanate. Then, a solution obtained by dissolving 0.2130 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 2.6731 g of acetonitrile was added to the contents in the flask, a Dimroth condenser was attached to the flask, and the contents in the flask were stirred at 70° C. for 1.5 hours in an oil bath.
A solution obtained by dissolving 0.48 g of p-methoxyphenol (MEHQ), 99.90 g (277.50 mmol) of polyethylene glycol monomethacrylate (average molecular weight: 360) and 0.1092 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 2.0494 g of acetonitrile was added to the contents in the flask, and the contents were stirred at 70° C. for 1 hour. A small amount of the thus obtained reaction solution was collected from the flask, and measured of an infrared absorption spectrum, whereby it was confirmed that a peak at 2350 cm−1 corresponding to a NCO group was disappeared.
The reaction solution was dissolved in 800 mL of acetonitrile, and transferred into a separating funnel. Then, 800 mL of hexane was added to the reaction solution in the separating funnel to separate the reaction solution into layers. Among two layers of the thus separated reaction solution, a lower layer (layer of acetonitrile) was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. A remaining layer of the reaction solution was collected, and 0.0119 g of 4-methoxy-1-naphthol (MNT) was added to the reaction solution. By distilling solvents away from the reaction solution under a reduced pressure, 121.29 g of a polysiloxane-based macromonomer (macromonomer G) in the form of a liquid having a high viscosity was obtained. The macromonomer G has a structure represented by the above-indicated general formula (VIII), wherein R51 is CH3— (methyl group), a is 6, b is 10 and n is 59, and an HLB value of the macromonomer G calculated according to the above-indicated formula is 1.54.
—Synthesis of Macromonomer H—
A 500 mL eggplant flask was charged with 115.11 g (67.27 mmol based on a functional group equivalent weight of 1711 g/mol) of a silicone which is modified with polypropylene oxide at both of its terminals (a number of repetition of an oxypropylene group is 10; a number of repetition of dimethylsiloxane is 40), and 37.38 g (168.17 mmol) of isophorone diisocyanate. The contents in the flask were stirred at the room temperature by using a stirrer, to dissolve the silicone in isophorone diisocyanate. Then, a solution obtained by dissolving 0.2001 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 2.5765 g of acetonitrile was added to the contents in the flask, a Dimroth condenser was attached to the flask, and the contents in the flask were stirred at 70° C. for 1.5 hours in an oil bath.
A solution obtained by dissolving 0.61 g of p-methoxyphenol (MEHQ), 152.69 g (336.32 mmol) of polyethylene glycol monomethacrylate (average molecular weight: 526) and 0.1079 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 1.8233 g of acetonitrile was added to the contents in the flask, and the contents were stirred at 70° C. for about 1 hour. A small amount of the thus obtained reaction solution was collected from the flask, and measured of an infrared absorption spectrum, whereby it was confirmed that a peak at 2350 cm−1 corresponding to a NCO group was disappeared.
The reaction solution was dissolved in 800 mL of acetonitrile, and transferred into a separating funnel. Then, 800 mL of hexane was added to the reaction solution in the separating funnel to separate the reaction solution into layers. Among two layers of the thus separated reaction solution, a lower layer (layer of acetonitrile) was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. A remaining layer of the reaction solution was collected, and 0.0112 g of 4-methoxy-1-naphthol (MNT) was added to the reaction solution. By distilling solvents away from the reaction solution under a reduced pressure, 100.13 g of a polysiloxane-based macromonomer (macromonomer H) in the form of a liquid having a high viscosity was obtained. The macromonomer H has a structure represented by the above-indicated general formula (VIII), wherein R51 is CH3— (methyl group), a is 10, b is 10 and n is 39, and an HLB value of the macromonomer H calculated according to the above-indicated formula is 3.08.
—Synthesis of Macromonomer I—
A 500 mL eggplant flask was charged with 98.20 g (100.82 mmol based on a functional group equivalent weight of 974 g/mol) of a silicone which is modified with polypropylene oxide at both of its terminals (a number of repetition of an oxypropylene group is 5; a number of repetition of dimethylsiloxane is 20), and 56.03 g (252.07 mmol) of isophorone diisocyanate. The contents in the flask were stirred at the room temperature by using a stirrer, to dissolve the silicone in isophorone diisocyanate. Then, a solution obtained by dissolving 0.1730 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 2.2347 g of acetonitrile was added to the contents in the flask, a Dimroth condenser was attached to the flask, and the contents in the flask were stirred at 70° C. for 1.5 hours in an oil bath.
A solution obtained by dissolving 1.32 g of p-methoxyphenol (MEHQ), 265.18 g (504.14 mmol) of polyethylene glycol monomethacrylate (average molecular weight: 526) and 0.0986 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 1.8672 g of acetonitrile was added to the contents in the flask, and the contents were stirred at 70° C. for about 1 hour. A small amount of the thus obtained reaction solution was collected from the flask, and measured of an infrared absorption spectrum, whereby it was confirmed that a peak at 2350 cm−1 corresponding to a NCO group was disappeared.
The reaction solution was dissolved in 800 mL of acetonitrile, and transferred into a separating funnel. Then, 800 mL of hexane was added to the reaction solution in the separating funnel to separate the reaction solution into layers. Among two layers of the thus separated reaction solution, a lower layer (layer of acetonitrile) was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. A remaining layer of the reaction solution was collected, and 0.0134 g of 4-methoxy-1-naphthol (MNT) was added to the reaction solution. By distilling solvents away from the reaction solution under a reduced pressure, 74.48 g of a polysiloxane-based macromonomer (macromonomer I) in the form of a liquid having a high viscosity was obtained. The macromonomer I has a structure represented by the above-indicated general formula (VIII), wherein R51 is CH3— (methyl group), a is 10, b is 5 and n is 19, and an HLB value of the macromonomer I calculated according to the above-indicated formula is 4.81.
—Synthesis of Macromonomer J—
A 1 L flask was charged with 294.6 g (0.1 mol) of dimethylpolysiloxane containing SiH groups at both of its terminals (a number of Si atoms is 40), 216.5 g (0.24 mol) of a copolymer of hexaethylene oxide and decapropylene oxide which is modified with an allyl group at its terminal, and 200 g of isopropyl alcohol, and a reaction was conducted for 4 hours under reflux of isopropyl alcohol, by using 0.03 g of a 3% ethanol solution of a neutralized chloroplatinic acid complex with vinyl siloxane, as a catalyst. After the reaction, it was confirmed that the SiH groups in dimethylpolysiloxane were completely disappeared.
By removing isopropyl alcohol under a reduced pressure, 500 g of a reaction product was obtained. Then, in order to remove the copolymer of hexaethylene oxide and decapropylene oxide which is modified with the allyl group at its terminal, remaining in the reaction product, the reaction product was reprecipitated by using 600 g of acetonitrile. Thereafter, a lower layer constituted by siloxane was collected, and further reprecipitated twice by using acetonitrile, whereby 420 g of a silicone which has polyether at both of its terminals and which does not contain unreacted polyether was obtained.
A 500 mL flask was charged with 237.5 g (0.05 mol) of the thus obtained silicone having polyether at both of its terminals, 0.03 g of iron acetylacetone, 0.15 g of dibutyl hydroxytoluene (BHT) and 0.6 g of p-methoxyphenol, and the contents in the flask were stirred at the room temperature for 1 hour, to disperse iron acetylacetone in the silicone. Then, 28.2 g (0.2 mol) of acryloylethyl isocyanate (Trade Name: Karenz AOI; available from SHOWA DENKO K.K., JAPAN) was dropped into the flask by using a dropping funnel. The flask was left at 40° C. for 3 hours, to complete an urethanization reaction.
Thereafter, acryloylethyl isocyanate remaining in the reaction solution was deactivated by using methanol. The thus obtained silicone solution was dissolved in an amount of hexane equal to that of the silicone solution, and the thus obtained hexane solution was washed three times by using acetonitrile which was used in the same amount as hexane. Then, 0.03 g of dibutyl hydroxytoluene (BHT) was added to an upper layer (layer of hexane) of the reaction solution which had been washed as described above. By distilling hexane away from the reaction solution under a reduced pressure, 203 g of a polysiloxane-based macromonomer (macromonomer J) in the form of a colorless and transparent liquid was obtained. The macromonomer J has a structure represented by the above-indicated general formula (IX), wherein a′ is 6, b′ is 10 and n is 39, and an HLB value of the macromonomer J calculated according to the above-indicated formula is 2.10.
—Synthesis of Macromonomer K—
A 500 mL eggplant flask was charged with 122.97 g (71.87 mmol based on a functional group equivalent weight of 1711 g/mol) of a silicone which is modified with polypropylene oxide at both of its terminals (a number of repetition of an oxypropylene group is 10; a number of repetition of dimethylsiloxane is 40), and 39.94 g (179.68 mmol) of isophorone diisocyanate. The contents in the flask were stirred at the room temperature by using a stirrer, to dissolve the silicone in isophorone diisocyanate. Then, a solution obtained by dissolving 0.2113 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 3.1027 g of acetonitrile was added to the contents in the flask, a Dimroth condenser was attached to the flask, and the contents in the flask were stirred at 70° C. for 1.5 hours in an oil bath.
A solution obtained by dissolving 0.65 g of p-methoxyphenol (MEHQ), 153.17 g (510.57 mmol) of polyethylene glycol monomethacrylate (average molecular weight: 300) and 0.1089 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 1.7292 g of acetonitrile was added to the contents in the flask, and the contents were stirred at 70° C. for about 1 hour. A small amount of the thus obtained reaction solution was collected from the flask, and measured of an infrared absorption spectrum, whereby it was confirmed that a peak at 2350 cm−1 corresponding to a NCO group was disappeared.
The reaction solution was dissolved in 800 mL of acetonitrile, and transferred into a separating funnel. Then, 800 mL of hexane was added to the reaction solution in the separating funnel to separate the reaction solution into layers. Among two layers of the thus separated reaction solution, a lower layer (layer of acetonitrile) was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. A remaining layer of the reaction solution was collected, and 0.0122 g of 4-methoxy-1-naphthol (MNT) was added to the reaction solution. By distilling solvents away from the reaction solution under a reduced pressure, 98.04 g of a polysiloxane-based macromonomer (macromonomer K) in the form of a liquid having a high viscosity was obtained. The macromonomer K has a structure represented by the above-indicated general formula (VIII), wherein R51 is CH3— (methyl group), a is 4, b is 10 and n is 39, and an HLB value of the macromonomer K calculated according to the above-indicated formula is 1.51.
—Synthesis of Comparative Macromonomer a—
A 500 mL eggplant flask was charged with 110.79 g (98.91 mmol based on a functional group equivalent weight of 1120 g/mol) of a silicone which is modified with polypropylene oxide at both of its terminals, and available from Shin-Etsu Chemical Co., Ltd. (Trade Name: X-22-4952; a number of repetition of an oxypropylene group is 10; a number of repetition of dimethylsiloxane is 20), and 33.08 g (148.8 mmol) of isophorone diisocyanate. The contents in the flask were stirred at the room temperature by using a stirrer, to dissolve the X-22-4952 in isophorone diisocyanate. Then, a solution obtained by dissolving 0.1799 g of tetrakis(2,4-pentanedionato)zirconium (IV) in 1.74 g of acetonitrile was added to the contents in the flask, and the contents were stirred at the room temperature for 30 minutes. Further, 33.55 g (29.96 mmol based on the functional group equivalent weight of 1120 g/mol) of the X-22-4952 was added to the contents in the flask, and the contents in the flask were stirred at the room temperature for 25 minutes. Thereafter, a Dimroth condenser was attached to the flask, and the contents in the flask were stirred at 70° C. for 2 hours in an oil bath. Then, a small amount of the thus obtained reaction solution was collected from the flask, and measured of 1HNMR, whereby it was confirmed that a signal (at about 3.1 ppm) of CH2 adjacent to a primary NCO group of isophorone diisocyanate was almost disappeared.
After adding 0.5641 g of p-methoxyphenol (MEHQ) and 42.86 g (297.3 mmol) of 4-hydroxybutyl acrylate to the reaction solution in the flask, the reaction solution was stirred at 70° C. for 1 hour. A small amount of the thus obtained reaction solution was collected from the flask, and measured of an infrared absorption spectrum, whereby it was confirmed that a peak at 2350 cm−1 corresponding to a NCO group was disappeared.
The reaction solution was dissolved in 800 mL of acetonitrile, and transferred into a separating funnel. Then, 800 mL of hexane was added to the reaction solution in the separating funnel to separate the reaction solution into layers. Among two layers of the thus separated reaction solution, a lower layer was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. Further, 400 mL of acetonitrile was added to the reaction solution to separate the reaction solution into layers again. Among two layers of the thus separated reaction solution, a lower layer was discarded. A remaining layer of the reaction solution was collected, and 0.0110 g of 4-methoxy-1-naphthol (MNT) was added to the reaction solution. By distilling solvents away from the reaction solution under a reduced pressure, 127.5 g of a polysiloxane-based macromonomer (comparative macromonomer a) in the form of a liquid having a high viscosity was obtained. The comparative macromonomer a has a structure represented by the above-indicated general formula (VIII), wherein R is H— (hydrogen atom), the part indicated as ( . . . )a is a butylene group (—CH2CH2CH2CH2—), b is 10 and n is 19, and an HLB value of the comparative macromonomer a calculated according to the above-indicated formula is 0.65.
—Synthesis of Comparative Macromonomer b—
A polysiloxane-based macromonomer (comparative macromonomer b) represented by a structural formula (X) given below was synthesized by a method similar to that used in Example 1 described in JP-A-2001-72739. An HLB value of the comparative macromonomer b calculated according to the above-indicated formula is 0.46.




—Synthesis of Comparative Macromonomer c—
A 1 L flask was charged with 146.6 g (0.1 mol) of dimethylpolysiloxane containing SiH groups at both of its terminals (a number of Si atoms is 20), 153.1 g (0.24 mol) of decapropylene oxide which is modified with an allyl group at its terminal (a number of repetition of an oxypropylene group is 10), and 150 g of isopropyl alcohol, and a reaction was conducted for 4 hours under reflux of isopropyl alcohol, by using 0.03 g of a 3% ethanol solution of a neutralized chloroplatinic acid complex with vinyl siloxane, as a catalyst. After the reaction, it was confirmed that the SiH groups in dimethylpolysiloxane were completely disappeared.
By removing isopropyl alcohol under a reduced pressure, 280 g of a reaction product was obtained. Then, in order to remove decapropylene oxide which is modified with the allyl group at its terminal, remaining in the reaction product, the reaction product was reprecipitated by using 500 g of acetonitrile. Thereafter, a lower layer constituted by siloxane was collected, and further reprecipitated twice by using acetonitrile, whereby 220 g of a silicone which has polyether at both of its terminals and which does not contain unreacted polyether was obtained.
A 500 mL flask was charged with 137.1 g (0.05 mol) of the thus obtained silicone having polyether at both of its terminals, 0.02 g of iron acetylacetone, 0.1 g of dibutyl hydroxytoluene (BHT) and 0.4 g of p-methoxyphenol, and the contents in the flask were stirred at the room temperature for 1 hour, to disperse iron acetylacetone in the silicone. Then, 28.2 g (0.2 mol) of acryloylethyl isocyanate (Trade Name: Karenz AOI; available from SHOWA DENKO K.K.) was dropped into the flask by using a dropping funnel. The flask was left at 40° C. for 3 hours, to complete an urethanization reaction.
Thereafter, acryloylethyl isocyanate remaining in the reaction solution was deactivated by using methanol. The thus obtained silicone solution was reprecipitated three times, by using 450 g of methanol and 90 g of water for each time of the reprecipitation. By removing the lowermost layer of the silicone solution reprecipitated as described above, 100 g of a polysiloxane-based macromonomer (comparative macromonomer c) in the form of a colorless and transparent liquid was obtained. The comparative macromonomer c is represented by a structural formula (XI) given below, and an HLB value of the comparative macromonomer c calculated according to the above-indicated formula is 0.57.




(In the above-indicated structural formula (XI), each of R71 and R72 is a hydrogen atom or a methyl group, wherein R72 is the methyl group in the case where R71 is the hydrogen atom, and R72 is the hydrogen atom in the case where R71 is the methyl group.)

—Synthesis of Comparative Macromonomer d—
A 3 L flask was charged with 193 g (0.5 mol) of 1,1,3,3-tetramethyl-1,3-methacryloxypropyl-disiloxane, 1480 g (5 mol) of octamethyl cyclotetrasiloxane and 0.28 g of trifluoromethanesulfonic acid, and the contents in the flask were reacted with each other at the room temperature for 5 hours. Then, 56 g of sodium bicarbonate was added to the thus obtained reaction solution in the flask, and the reaction solution was neutralized at the room temperature for 2 hours. Thereafter, the reaction solution was purified by filtration.
By adding 0.06 g of dibutyl hydroxytoluene (BHT) to the thus filtered reaction solution, and removing dimethyl cyclics generated as a by-product at a temperature of 120° C., 1500 g of a comparative macromonomer d was obtained. The comparative macromonomer d is represented by a structural formula (XII) given below, and an HLB value of the comparative macromonomer d calculated according to the above-indicated formula is 0.52.




The polysiloxane-based macromonomers synthesized as described above were tested as described below.
There were prepared 20 kinds of polymerizable composition (polymerization liquid) including components at respective proportions indicated in Tables 1 to 3 given below. Each of the thus prepared polymerization liquids was accommodated in a mold which has a thickness of 0.2 mm and which is formed of polypropylene. Each of the polymerization liquids of Examples 1 to 13, Comparative Examples 1 to 5 and 7 was photopolymerized by irradiating the mold accommodating the polymerization liquid with a visible ray having a wavelength of 405 nm with an illumination intensity of 3 mW/cm2 for 30 min, by using a fluorescent tube (TL 20W/03 RS AQUA CORAL, available from Philips Electronics Japan Ltd.). On the other hand, the polymerization liquid of Comparative Example 6 was polymerized by irradiating the mold accommodating the polymerization liquid with an ultraviolet ray with an illumination intensity of about 10 mW/cm2 for about 20 min, by using an ultraviolet-ray irradiation apparatus (ultraviolet-ray curing apparatus UBX0302-03 available from EYE GRAPHICS CO., LTD., JAPAN) equipped with an ultraviolet-ray lamp having a main wavelength at 365 nm.
















TABLE 1







Example 1
Example 2
Example 3
Example 4
Example 5
Example 6
Example 7
Example 8

























Proportion
Kind of
Macromono-
Macromono-
Macromono-
Macromono-
Macromono-
Macromono-
Macromono-
Macromono-


(part by
macromonomer
mer A
mer B
mer C
mer D
mer E
mer F
mer G
mer H


weight)
Proportion
22
22
22
22
22
22
22
22



TRIS
33
33
33
33
33
33
33
33



N-MMP
25
25
25
25
25
25
25
25



DMAA
20
20
20
20
20
20
20
20



HMEPBT
2
2
2
2
2
2
2
2



TPO
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3






















TABLE 2







Example 9
Example 10
Example 11
Example 12
Example 13






















Proportion
Kind of
Macromono-
Macromono-
Macromono-
Macromono-
Macromono-


(part by
macromonomer
mer F
mer H
mer I
mer J
mer K


weight)
Proportion
17
17
22
28
22



TRIS
39
39
33
28
33



N-MMP
—
—
25
34
25



DMAA
44
44
20
10
20



HMEPBT
2
2
2
2
2



TPO
0.3
0.3
0.3
0.3
0.3
























TABLE 3







Comparative
Comparative
Comparative
Comparative
Comparative
Comparative
Comparative



Example 1
Example 2
Example 3
Example 4
Example 5
Example 6
Example 7
























Proportion
Kind of
Comparative
Comparative
Comparative
Comparative
Comparative
Comparative
Comparative


(part by
macromonomer
Macromono-
Macromono-
Macromono-
Macromono-
Macromono-
Macromono-
Macromono-


weight)

mer a
mer b
mer c
mer d
mer b
mer b
mer c



Proportion
35
35
28
28
22
35
22



TRIS
25
25
28
28
33
20
33



N-MMP
25
25
34
34
25
33
25



DMAA
15
15
10
10
20
12
20



HMEPBT
2
2
2
2
2
—
2



TPO
0.3
0.3
0.3
0.3
0.3
—
0.3



HMPPO
—
—
—
—
—
0.4
—



EDMA
—
—
—
—
—
0.4
—









After the polymerization, polymers were taken out of the molds, whereby specimens (Examples 1 to 13 and Comparative Examples 1 to 7) in the form of plates were obtained. The specimens were immersed in distilled water at the room temperature over a night for hydration, and appearances of the hydrated specimens were visually observed. It was recognized that the polymers of Examples 1 to 13 and Comparative Example 6 are transparent enough to permit their use as the ophthalmic lens. On the other hand, the polymers of Comparative Examples 1 to 5 and 7 were clouded or slightly clouded, and recognized as unsuitable for their use as the ophthalmic lens.
The specimens of Examples 1 to 13 and Comparative Example 6, which were recognized as transparent by the visual observation, were immersed in another mass of distilled water for not shorter than 4 hours, after the above-described hydration treatment. Then, the specimens in the form of plates were immersed in an isotonic sodium chloride solution, and subjected to autoclave sterilization.
The specimens subjected to the hydration treatment and the sterilization treatment were formed into a configuration (of a dumbbell) shown in FIG. A. 2 of JIS-K-7162-1994 “Plastics—Determination of tensile properties—Part 2: Test conditions for moulding and extrusion plastics”. The thickness of the specimens in the form of the dumbbell is about 0.34 mm. The specimens in the form of the dumbbell were subjected to a tensile test (test speed: 20 mm/min) in the isotonic sodium chloride solution, to obtain the young's modulus and the stress relaxation rate, and to calculate the value β (=young's modulus/stress relaxation rate), results of which are indicated in Table 4 given below.









TABLE 4









Polymer













Macro-

Stress





monomer
Young's
relax-












HLB
modulus
ation















β
value
[Mpa]
rate [%]
α
Appearance

















Example 1
1.25
2.72
0.73
14.9
0.0490
Transparent


Example 2
1.82
3.19
0.93
14.1
0.0660
Transparent


Example 3
0.91
2.30
0.64
15.0
0.0427
Transparent


Example 4
1.82
1.74
0.57
14.7
0.0388
Transparent


Example 5
3.64
2.21
0.64
14.6
0.0438
Transparent


Example 6
2.50
1.97
0.55
14.8
0.0372
Transparent


Example 7
3.75
1.54
0.42
15.3
0.0275
Transparent


Example 8
2.00
3.08
0.50
15.0
0.0333
Transparent


Example 9
2.50
1.97
0.48
17.4
0.0276
Transparent


Example 10
2.00
3.08
0.44
18.1
0.0243
Transparent


Example 11
1.33
4.81
0.83
14.7
0.0565
Transparent


Example 12
2.50
2.10
0.55
14.0
0.0393
Transparent


Example 13
2.86
1.51
0.61
12.1
0.0504
Transparent


Comparative
—
0.65
—
—
—
Clouded


Example 1


Comparative
20.0
0.46
—
—
—
Clouded


Example 2


Comparative
—
0.57
—
—
—
Clouded


Example 3


Comparative
—
0.52
—
—
—
Clouded


Example 4


Comparative
20.0
0.46
—
—
—
Clouded


Example 5


Comparative
20.0
0.46
1.17
 9.7
0.1206
Transparent


Example 6


Comparative
—
0.57
—
—
—
Slightly


Example 7





clouded









As is apparent from Table 4, it is recognized that as the polymer of the ophthalmic lens according to the invention, the polymers produced by using the predetermined polysiloxane-based macromonomers can have the young's modulus and the stress relaxation rate, which are held within the respective predetermined ranges, and those polymers can be produced by using a wide variety of compositions. On the other hand, the polymers produced by using polysiloxane-based macromonomers other than the predetermined polysiloxane-based macromonomers are clouded although the compositions used in the production of those polymers are the same as those used in the production of the polymers using the predetermined polysiloxane-based macromonomers, except for the polysiloxane-based macromonomers. It is also recognized that in the case where a polymer is produced by using a polysiloxane-based macromonomer other than the predetermined polysiloxane-based macromonomer and a composition which makes the polymer transparent enough to permit its use as the ophthalmic lens, it is difficult to make the polymer have the young's modulus and the stress relaxation rate, which are held within the respective ranges adequate for its use as the ophthalmic lens.

## Claims

1. An ophthalmic lens formed of a polymer having a young's modulus of 0.3-1.0MPa and a stress relaxation rate of 10-20%, where the polymer is obtained from a polymerizable composition including a polysiloxane-based macromonomer having at least one polymerizable group and a polysiloxane chain having a siloxane unit as a repeating unit, wherein
the polysiloxane-based macromonomer has:
a polyoxyethylene chain having an oxyethylene group as a repeating unit, wherein a number of repetition of the oxyethylene group is “a”, and “a” is an integer not smaller than two, and
a polyoxyalkylene chain having an oxyalkylene group other than the oxyethylene group as a repeating unit, wherein a number of repetition of the oxyalkylene group is “b”, and “b” is an integer not smaller than two; and

the polysiloxane-based macromonomer has a value β calculated according to the following formula (B) being held within a range from 0.5 to 5.0:


β=n/(“a”+“b”)  (B)

where
n represents a total number of Si atoms in a molecule of the polysiloxane-based macromonomer; wherein


the at least one polymerizable group is bonded to the polysiloxane chain constituting a main chain of a molecule of the polysiloxane-based macromonomer, through at least one urethane bond.

2. The ophthalmic lens according to claim 1, wherein a value αcalculated according to the following formula (A) is held within a range from 0.02 to 0.10:


α=E/r  (A)

wherein E represents the young's modulus (MPa) of the polymer of the ophthalmic lens, and r represents the stress relaxation rate (%) of the polymer.

3. The ophthalmic lens according to claim 1, wherein an HLB value of the polysiloxane-based macromonomer calculated according to the following formula (C) is held within a range from 0.7 to 6.0:


[HLB value]=WE/5  (C)

wherein WE represents a weight fraction (wt %) of the oxyethylene group in the molecule of the polysiloxane-based macromonomer.

4. The ophthalmic lens according to claim l wherein the number “a” of repetition of the oxyethylene group is within a range from 4 to 15.

5. The ophthalmic lens according to claim 1, wherein the polyoxyalkylene chain is a polyoxypropylene chain having an oxypropylene group as a constituent unit.

6. The ophthalmic lens according to claim 5, wherein a number of repetition of the oxypropylene group is within a range from 5 to 16.

7. The ophthalmic lens according to claim 1, wherein the polysiloxane chain, the polyoxyethylene chain and the polyoxyalkylene chain constitute a main chain of the molecule of the polysiloxane-based macromonomer.

8. The ophthalmic lens according to claim 1, wherein the polysiloxane-based macromonomer is represented by the following general formula (I):


A1-Z1—U1—Z2—Z3—(—S1—U2—)n—S2—Z4—Z5—U3—Z6-A2  (I)


where
n is 0 or an integer within the range from 1 to 10;
A1 is a group represented by a general formula (II):


Y21—R21—  (II)

where
Y21 represents an acryloyloxy group, a methacryloyloxy group, a vinyl group or an allyl group, independently of each other, and
R21 represents a direct bond or a linear or branched alkylene group having 2 to 6 carbon atoms, independently of each other;


A2 is a group represented by a general formula (III):


—R22—Y22  (III)

where
Y22 represents an acryloyloxy group, a methacryloyloxy group, a vinyl group or an allyl group, independently of each other, and
R22 represents a direct bond or a linear or branched alkylene group having 2 to 6 carbon atoms, independently of each other;


each of Z1, Z2, Z3, Z4, Z5 and Z6 represents a direct bond or a polyoxyalkylene chain having an oxyalkylene group as a repeating unit, independently of one another, wherein at least one of Z1 to Z6 is the polyoxyethylene chain in which the number of repetition of the oxyethylene group is two or more, and at least one of Z1 to Z6 which is not the polyoxyethylene chain is the polyoxyalkylene chain having the oxyalkylene group other than the oxyethylene group as the repeating unit;
U1 is a group represented by a general formula (IV):


-E21-X21—  (IV)



and includes the urethane bond in the molecular chain of the polysiloxane-based macromonomer, where in the general formula (IV)
X21 represents an oxygen atom, and
E21 represents
a —NHCO— group, wherein E21 forms the urethane bond with X21, or
a divalent group derived from a diisocyanate selected from a group consisting of saturated aliphatic diisocyanates, unsaturated aliphatic diisocyanates, alicyclic diisocyanates and aromatic diisocyanates, wherein E21 forms the urethane bond with each of Z1 and X21;

U2 is a group represented by a general formula (VI):


—R41—X41-E41-X42—R42—  (VI)



and includes the urethane bond in the molecular chain of the polysiloxane-based macromonomer, where the general formula (VI)
each of R41 and R42 represents a linear or branched alkylene group having 2 to 6 carbon atoms, independently of each other, and
each of X41 and X42 represents an oxygen atom or an alkylene glycol group, independently of each other, and E41 represents a divalent group derived from a diisocyanate selected from the group consisting of saturated aliphatic diisocyanates, unsaturated aliphatic diisocyanates, alicyclic diisocyanates and aromatic diisocyanates, wherein E41 forms the urethane bond with each of X41 and X42;
U3 is a group represented by a general formula (VII):


—X22-E22-  (VII)



and includes the urethane bond in the molecular chain of the polysiloxane-based macromonomer, where in the general formula (VII)
X22 represents an oxygen atom, and
E22 represents
the —NHCO — group, wherein E22 forms the urethane bond with X22, or
a divalent group derived from a diisocyanate selected from the group consisting of saturated aliphatic diisocyanates, unsaturated aliphatic diisocyanates, alicyclic diisocyanates and aromatic diisocyanates, wherein E22 forms the urethane bond with each of Z5 and X22; and

each of S1 and S2, which are independent of each other, is a group represented by a general formula (V):




where
each of R31 and R38 represents a linear or branched alkylene group having 2 to 6 carbon atoms, independently of each other, and
each of R32, R33, R34, R35, R36 and R37 represents an alkyl group having 1 to 6 carbon atom(s), a fluorine-substituted alkyl group or a phenyl group, independently of one another,
K is an integer within a range from 1 to 1500, and
L is 0 or an integer within a range from 1 to 1500, wherein a sum of K and L:


K+L




is an integer within the range from 1 to 1500.

9. The ophthalmic lens according to claim 1, wherein the polysiloxane-based macromonomer is represented by one of the following general formulas (VIII), (IX) and (XIII):



where
R51 represents a hydrogen atom or a methyl group,
a is an integer not smaller than two,
b is an integer not smaller than two,
n is an integer within a range from 1 to 1500, and
each of R52 and R53 is a hydrogen atom or a methyl group, wherein
if R53 is a methyl group then R52 is a hydrogen atom, and
if R53 is a hydrogen atom then R52 is a methyl group;






where
a′ is an integer not smaller than two,
b′ is an integer not smaller than two,
n′ is an integer within a range from 1 to 1500, and
each of R61 and R62 is a hydrogen atom or a methyl group, wherein
if R62 is a methyl group then R61 is a hydrogen atom, and
if R62 is a hydrogen atom then R61 is a methyl group; and






where
a′′ is an integer not smaller than two,
b′′ is an integer not smaller than two,
n′′ is an integer within a range from 1 to 1500, and
each of R81 and R82 is a hydrogen atom or a methyl group, wherein
if R82 is a methyl group then R81 is a hydrogen atom, and
if R82 is a hydrogen atom then R81 is a methyl group.