SILICONE-CONTAINING POLYMER SUITABLE FOR OPHTHALMIC APPLICATIONS

Abstract: Copolymers formed from dimethacrylates of polyalkylene glycols and vinylic reactive silicones having up to 20 silicon atoms in the substantial absence of additional cross-linking agents are disclosed. The copolymers may include a hydrophilicity-modifying monomer. The preferred silicon is TRIS (i.e., 3-methacryloxypropyl tris(trimethylsiloxy)silane), while the preferred polyalkylene glycol is polypropylene glycol dimethacrylate. The copolymers are especially suited to use in the fabrication of soft contact lenses because of the good durability and high oxygen permeability.

Description: SILICONE-CONTAINING POLYMER SUITABLE FOR OPHTHALMIC APPLICATIONS This invention relates to polymers suited for formation of a contact lens. More specifically, this invention relates to organosilicone-polyalkylene glycol copolymers suitable for use in fabrication of soft contact lenses. Contact lenses may generally be classified into two categories. The first category, hard contact lenses, developed significantly in the 1940's with the advent of poly(methyl methacrylate) lenses. Hard contact lenses have certain advantageous properties, but are generally less comfortable for the consumer. The second category, soft contact lenses, were developed primarily as a result of the discovery of poly-HEMA or poly(2-hydroxyethyl methacrylate). Although soft contact lenses improve patient comfort, such lenses suffer from durability problems. Further, soft lenses generally require a high water content in order to achieve sufficient oxygen permeability to maintain corneal health during extended wear periods. One goal of soft contact lenses is high oxygen permeability. High oxygen permeability is required because the cornea replenishes depleted oxygen by absorbing oxygen from the tear film, whose oxygen originates from the surrounding air. A contact lens covering the cornea reduces oxygen availability to the cornea, unless the lens is sufficiently permeable to oxygen. Thus, substantial efforts have been devoted to producing contact lenses which are soft and have a high oxygen permeability. Improvements in oxygen permeability have been achieved with the use of polysiloxane materials, especially polydimethylsiloxanes. However, these materials are inherently non- wettable, or hydrophobic. Polysiloxanes have been copolymerized with hydrophilic materials to produce contact lenses because the hydrophobic nature of polysiloxanes adversely affects patient comfort. An example of a polysiloxane copolymer material suited to the formation of hard contact lenses is disclosed in EP-A2-108,886 by inventors Leboeuf and Singer. This reference discloses a hard contact lens material which is a copolymer of (a) 15-40% tris(trimethyl- siloxyl) methacryloxypropyl silane (i.e., TRIS), (b) 10-80% cross-linking agent, (c) up to 60% alkanol ester and or hydrophilic monomer. An example of a polysiloxane copolymer material suited to the formation of soft contact lenses is disclosed in EP-A2-493.320 by inventors Mueller and Plankl. This reference discloses a soft contact lens material which is the copolymerization product of (a) 15-69.9% of a vinyl-telechelic polyether, (b) 30-84.9% of a fluorinated, ethylenically unsaturated monomer, a silicone-containing ethylenically unsaturated monomer, or a mixture thereof, (c) up to 40% of another ethylenically unsaturated monomer, and (d) 0.1 to 10% of a polyethylenically unsaturated comonomer (i.e., a cross-linking agent). The vinyl-telechelic polyether may include a polyethylene or polypropylene oxide. One of the preferred (b) monomers is tris (trimethylsiloxy-silyl) propyl methacrylate (i.e., TRIS). One problem arising with the use of siloxanes (e.g., TRIS) in the formation of soft contact lenses is that the polymeric material includes cross-linking agents for increasing polymer durability. The addition of such cross-linking agents decreases the oxygen permeability (Dk) of the lenses. Thus, there is a continuing need for a soft contact lens having increased oxygen permeability and providing good patient comfort. An object of the invention is to provide a polymeric material suited to the formation of soft contact lenses having high oxygen permeability, good hydrophilicity, good durability, good visual clarity and patient comfort. Another object of the invention is to provide a process for producing a soft contact lens in the substantial absence of added cross-linking agents, while maintaining high oxygen permeability and good durability. One embodiment of the invention is a copolymer having good durability, high oxygen permeability, ocular biocompatibility, good optical clarity, and good hydrophilicity. The copolymer is formed from a monomer mixture including (a) 50 to 95 percent by weight vinylic reactive silicone having up to 20 silicon atoms and (b) 5 to 50 percent by weight divinylic polyalkylene glycol in the absence or substantial absence of additional cross-linking agents. The term "additional crosslinking agents" in this context is to be understood in a way that it refers to crosslinking agents other than vinylic reactive silicon and divinylic polyalkylene glycols. The copolymer may include a hydrophilicity modifier, such as a hydrophobe or hydrophile, to properly attenuate the hydrophilicity to the desired level. Preferably, the vinylic reactive silicone is 3-methacryloxypropyl tris(trimethylsiloxy) silane, while the preferred divinylic polyalkylene glycol is polypropylene glycol dimethacrylate. Another embodiment of the invention is a hydrophilic (soft) contact lens formed from the aforementioned copolymer. The contact lens preferably includes 10 to 50 weight percent water. Still another embodiment of the invention is a process for forming a soft contact lens in the substantial absence of added cross-linking agent. The process involves first forming a mixture of a vinylic reactive silicone having up to 20 silicon atoms with a divinylic polyalkylene glycol in the substantial absence of additional cross-linking agents. The mixture is placed in a contact lens mold under conditions sufficient to polymerize the silicone and polyalkylene glycol monomers, thereby forming a soft contact lens. One embodiment of the invention is a copolymer having an advantageous balance of mechanical durability, oxygen permeability, and visual clarity. This polymeric material is useful in the formation of visual correction devices, preferably contact lenses, because of these advantageous properties. Another embodiment of the invention is a soft contact lens formed from the silicone/polyalkylene glycol copolymer. The polymeric materials or the contact lenses of the present invention preferably have a Dk of at least 70, more preferably a Dk of at least 75, even more preferred a Dk of at least 78, and most preferred a Dk of at least 80. A third embodiment of the invention is a process for forming a contact lens having high oxygen permeability. The monomers required in preparation of copolymers of the instant invention include (A) one or more vinylic-reactive silicones having up to 20 silicon atoms and (B) one or more difunctional polyalkylene glycol monomers. The monomeric weight percentage of vinylic reactive silicone may range from about 50 to 95 percent, more preferably about 60 to 80 percent, while the weight percentage of polyalkylene glycol may range from about 5 to 50 percent, more preferably about 20 to 40 percent. In one embodiment, the copolymer includes one or more hydrophilicity modifiers, such as those disclosed in US-A-4,921 ,956 (Molock et al.), which are hereby incorporated by reference. The copolymer may include from about 0.5 to 40, more preferably about one to 40, even more preferably about 1 to 30, weight percent hydrophilic modifier. In case such a modifier is present, the upper limitation of the divinylic polyalkylene glycol monomer is about 49.5 weight percent, more preferred about 49 weight percent. Advantageously, the copolymerization of the silicone-containing monomer and polyalkylene glycol is accomplished in the absence of added cross-linking agents. Although the difunctional polyalkylene glycol may function as a cross-linking agent itself, the polyalkylene glycol is intended primarily to copolymerize with the vinylic-reactive silicone. By polymerizing in the substantial absence of additional cross-linking agents, the present invention yields contact lenses having increased oxygen permeability (Dk) without adversely affecting durability as compared to prior art processes which require added cross-linking agents. Preferably, the present process is entirely free of added cross-linking agents. SILICONE-CONTAINING MONOMER (A): "Vinylic-reactive silicones", as used herein, refers to monomers, oligomers, or macromers having siloxane groups and vinyl groups (unsatur¬ ated carbon-carbon double bonds) capable of reacting with other reactive groups to form a chemical bond with one of the carbon atoms. The vinyl-reactive silicones useful in accordance with the present invention include those having less than about 20 silicon atoms, more preferably less than about 10 silicon atoms, and even more preferably less than 7 silicon atoms. Examples of such vinylic-reactive silicones include, without limitation thereto, 3-methacryloxypropyl tris(trimethylsiloxy) silane; 3-methacryloxypropyl-bis(trimethyl- siloxy)methylsilane; and 3-methacryloxypropyl-pentamethyldisiloxane; and mixtures thereof. A particularly preferred vinylic-reactive silicone is 3-methacryloxypropyl tris(tri methylsiloxy) silane [CAS No. 17096-07-0], also known as TRIS. DIFUNCTIONAL POLYALKYLENE GLYCOL MONOMER (B): The difunctional (or divinylic) polyalkylene glycol monomers useful in accordance with the present invention include, without limitation thereto, dimethacrylates of polyethylene glycols, dimethacrylates of polypropylene glycols, distyrenic-capped polyethylene glycols, distyrenic-capped poly¬ propylene glycols, dimethacrylates of tetramethylene glycol and combinations thereof. Preferably the weight average molecular weight range of the polyalkylene glycol is about 425 to about 4000. Specifically polypropylene glycol, and even more preferred POLY¬ PROPYLENE GLYCOL 4000, available from Dow Chemical (Midland, Ml), is a particularly preferred polyalkylene glycol. It is further preferred that the dimethacrylate of a polyalkylene glycol also comprises one or more urethane bonds. A dimethacrylate of a polyalkylene glycol can be prepared by mixing a methacrylate with the polyalkylene glycol in the presence of a catalyst at room temperature. Such dimethacrylate can be obtained e.g. by reaction of a polyalkylene glycol with a vinylic monoisocyanate. For example, polypropylene glycol may be mixed with isocyanatoethyl methacrylate in the presence of about 0.01 to 0.05 weight percent dibutyltin dilaurate catalyst. The resulting polypropylene glycol has methacrylate end groups which impart free radical addition polymerization reactivity to the adduct. HYDROPHILICITY MODIFIERS: Hydrophilicity modifiers useful in accordance with the present invention include hydrophobes and hydrophiles, with the latter being preferred. A preferred group of hydrophilic modifiers includes those defined by the formula X-T-G wherein the hydrophilic group G typically has one or more free or etherified hydroxy groups, amino groups, amides, urethanes and/or other typically hydrophilic groups; X is a polymerizable or reactive moiety selected from ethylenically unsaturated radicals, preferably vinyl, 1 - or 2-lower alkyl vinyl, more preferably 1 -methyl vinyl, or 2-methyl vinyl, or allyl; and T is generally a divalent linking group which can be selected from a wide variety of divalent groups that can be linked both to G and to X. These hydrophilicity modifiers are described more fully in US-A-4,921 ,956, which is incorporated herein by reference. Other hydrophiles useful in accordance with the present invention include, without limitation thereto, monomers selected from the group consisting of dimethyl acrylamide, 2- hydroxyethyl methacrylate, N-vinyl pyrrolidone, monomethacrylated polyethylene glycols, monomethacrylated polypropylene glycols, and mixtures thereof. Other hydrophobes useful in accordance with the present invention include, without limitation thereto, monomers selected from the group consisting of methyl methacrylate, vinylic-reactive fluorinated monomers, such as hexafluoroisopropyl methacrylate, styrenic monomers, isobornyl methacrylate, and mixtures thereof. CONTACT LENS FORMATION PROCESS: Contact lenses may be formed from the aforementioned monomers by a variety of processes. Preferably, contact lenses are formed by polymerizing a prepolymerization mixture including the silicone, polyalkylene glycol, and optionally hydrophilic modifier, in a contact lens mold, which is preferably a double-sided lens mold. The polymerization may be initiated by addition of a polymerization initiator, such as DAROCUR® 1 173, available from EM Chemicals (Hawthorne, NJ). The prepolymerization mixture may be prepared by admixing the desired monomers together with a solvent, such as, without limitation, isopropyl alcohol. Prior to the lens molding process, the monomer solution should be prepared and stored under conditions adverse to polymerization. Preferably, the monomer solution is polymerized shortly after application to the lens molding fixture. The monomer solution may be prepared by admixing about 50 to 95 weight percent vinylic reactive silicone to 5 to 50 weight percent divinylic polyalkylene glycol, based on the weight of the monomers, in the presence of solvent. The solvent concentration should be sufficiently high to produce a monomer solution having a viscosity low enough to allow sufficient flow, while not so high that problems with subsequent solvent extraction processes result. The monomer solution may have about one to about ten weight percent solvent, more preferably two to five percent, based on total solution weight. Suitable solvents include isopropyl alcohol and methylethyl ketone. A polymerization initiator, such as DAROCUR® 1173 may be added to the monomer mixture to initiate polymerization. The polymerization initiator is preferably added in an amount of up to about 0.05 gram per gram of total monomer, more preferably about 0.003 g/g monomer. Thus, preparation of a contact lens in accordance with the present invention may occur by the following process. First, a vinylic reactive silicone having up to 20 silicon atoms is contacted with a divinylic polyalkylene glycol in the presence of solvent and a polymerization initiator, thereby forming a prepolymerization mixture. The prepolymerization mixture is placed in a contact lens mold, preferably double-sided, under conditions sufficient to cause copolymerization of the polyalkylene glycol with the silicone in the substantial absence of cross-linking agents. Ultraviolet light is applied to the mixture at an intensity sufficient to initiate the polymerization process. The copolymerization process is allowed to proceed to completion in the substantial absence of added cross-linking agents, thereby yielding a contact lens having a shape defined substantially by the mold. The previous disclosure will enable one having ordinary skill in the art to practice the invention. In order to better enable the reader to understand specific embodiments and the advantages thereof, reference to the following examples is suggested. Temperatures are given in degrees Celsius. EXAMPLE 1 : In order to impart reactivity, isocyanatoethyl methacrylate end groups are bonded to polypropylene glycols having a range of molecular weights from about 425 to 4000. While maintaining anhydrous conditions, about 20 g (about 0.05 g-mol) of POLY- PROPYLENE GLYCOL 4000 (available from DOW CHEMICAL CO., Midland, Ml) is added to a flame dried 500 ml 3-neck round bottom flask cooled to about 23 °C. About 1.55 g (about 0.01 g-mol) of isocyanatoethyl methacrylate (available from MONOMER POLYMER, INC., Windham, NH) and about 0.004 g (about 0.02 weight percent) dibutyltiπ dilaurate catalyst (available from PHALTZ BAUER, Waterbury, CT) are added to the flask. The flask is gently manually swirled, then covered with foil to minimize light contact, and slowly mechanically stirred at room temperature in a nitrogen atmosphere overnight. The resulting polypropylene glycols, having methacrylate end groups, (polypropylene glycol dimethacrylate) have weight-average molecular weights of about 425 to 4000. Polyethyleneglycol dimethacrylates having weight-average molecular weights of about 200, 400 and 600 are commercially available from Monomer Polymer Labs (Windham, NH). EXAMPLE 2: Polypropylene glycol dimethacrylate ("PPG") having a molecular weight of about 4000 is prepared substantially as described in Example 1. About 0.80 g of the polypropylene glycol dimethacrylate is added to about 1.2 g of 3-methacryloxypropyltris (trimethylsiloxy) silane (i.e., TRIS, available from GELESTE, Tullytown, PA), and about 0.05 cc of DAROCUR® 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is polymerized, or cured, in a nitrogen atmosphere by applying ultraviolet (UV) light at an intensity sufficient to drive the copolymerization to substantial completion after an application period of about 3 hours. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the previously- described procedure are evaluated for oxygen permeability. Oxygen fluxes (J) are measured at 34 °C in a wet cell (i.e., gas streams are maintained at about 100% relative humidity) using a Dk1000 instrument (available from Applied Design and Development Co., Norcross, Georgia). An oxygen stream is passed across one side of the lens at a rate of about 20 cm 3 /min., while a nitrogen stream is passed on the opposite side of the lens at a rate of about 15 cm^/min. The oxygen concentration in the nitrogen stream (i.e., oxygen which diffuses through the lens) is measured at equilibrium conditions. D^, a measure of the oxygen permeability of a material, is then determined from the following formula: D k = Jt (P oxygen ) where J = oxygen flux [microliters O2/cm*---minute] p oxygen = ( p measured " p water vapor)( %0 2 in test gas) [mm Hg] p measured = barometric pressure [mm Hg] p water vapor = 0 mm Hg at 34 °C (in a dry cell) [mm Hg] p water vapor - 40 +/" 1 mm H 9 at 34C<* - * ( in a wet ce ") [ mm H 9l t = thickness of lens material [mm] where Dk, as reported herein, has units of [(cc 02)(mm/cm 2 )(cm sec)(mmHg) x 10 "10 ]. Fully hydrated contact lenses prepared in accordance with the procedures of Example 1 have a Dk of about 87 and a modulus of elasticity of about 1.6 megaPascals (MPa). EXAMPLE 3 (COMPARATIVE): Polypropylene glycol dimethacrylate having a molecular weight of about 4000 is prepared substantially as described in Example 1. About 0.80 g of the polypropylene glycol dimethacrylate (PPG) is added to about 1.1 g of TRIS, to about 0.10 g ethyleneglycol dimethacrylate ("EGDMA", available from Sartomer, West Chester, PA) and about 0.05 cc of DAROCUR® 1 173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is polymerized, or cured, in a nitrogen atmosphere by applying ultraviolet (UV) light at an intensity sufficient to drive the copolymerization to substantial completion after an application period of about 3 hours. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the procedures of Comparative Example 3 have a Dk of about 70 and a modulus of elasticity of about 10.9 MPa. EXAMPLE 4 (COMPARATIVE): Polypropylene glycol dimethacrylate having a molecular weight of about 4000 is prepared substantially as described in Example 1. About 0.70 g of the polypropylene glycol dimethacrylate (PPG) is added to about 1.2 g of TRIS, to about 0.10 g EGDMA, and about 0.05 cc of DAROCUR® 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is polymerized, or cured, in a nitrogen atmosphere by applying ultraviolet (UV) light at an intensity sufficient to drive the copolymerization to substantial completion after an application period of about 3 hours. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the procedures of Comparative Example 4 have a Dk of about 45 and a modulus of elasticity of about 13.8 MPa. Table I summarizes the characteristics of contact lenses formed in accordance with the procedures of Examples 2 and Comparative Examples 3 and 4. TABLE I Example Monomers Dk Modulus 2 0.80 g PPG 4000, 1.2 g TRIS 87 1.6 3 0.80 g PPG 4000, 1.1 g TRIS, 0.10 g EGDMA 70 10.9 4 0.70 g PPG 4000, 1.2 g TRIS, 0.10 g EGDMA 45 13.8 Example 2 describes the preparation of a polypropyleneglycol-TRIS copolymer contact lens having a Dk of about 87. Examples 3 and 4 describe the preparation of similar contact lenses with the addition of ethyleneglycol dimethacrylate as a cross-linking agent that increases mechanical properties. The Dk achieved with added cross-linking agent is disadvantageously reduced in both Examples 3 and 4, in comparison to Example 2. However, the modulus of elasticity of the Example 2 contact lens remains acceptable in the absence of additional cross-linking agents. Thus, Example 2 and Comparative Examples 3 and 4 illustrate that contact lenses having a higher oxygen permeability (Dk) and acceptable mechanical properties can be achieved by copolymerization of polyalkyleneglycol dimethacrylates with TRIS in the absence of additional conventional cross-linking agents, such as ethyleneglycol dimethacrylate (EGDMA). EXAMPLE 5: Polypropylene glycol dimethacrylate having a molecular weight of about 4000 is prepared substantially as described in Example 1. About 0.59 g of the polypropylene glycol dimethacrylate is added to about 0.70 g of TRIS, about 0.01 g of hydrophobic monomer hexafluoroisopropylmethacrylate (i.e., "HFIM", available from Polysciences, Warrington, PA), and about 0.05 cc of DAROCUR® 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is polymerized, or cured, in a nitrogen atmosphere by applying ultraviolet (UV) light at an intensity sufficient to drive the copolymerization to substantial completion after a period of about 3 hours. The resultant contact lens is removed from the mold and hydrated. - - 10 - Fully hydrated contact lenses prepared substantially in accordance with the procedures of Example 5 have a Dk of about 87. EXAMPLE 6: Polypropylene glycol dimethacrylate having a molecular weight of about 4000 is prepared substantially in accordance with the procedure described in Example 1. About 0.29 g of the polypropylene glycol dimethacrylate is added to about 0.70 g of TRIS, about 0.01 g of HFIM, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the previously-described procedure have a Dk of about 88. EXAMPLE 7: Polypropylene glycol dimethacrylate having a molecular weight of about 4000 is prepared substantially in accordance with the procedure described in Example 1. About 0.28 g of the polypropylene glycol dimethacrylate is added to about 0.70 g of TRIS, about 0.02 g of HFIM, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the previously-described procedure have a Dk of about 85. EXAMPLE 8: Polypropylene glycol dimethacrylate having a molecular weight of about 4000 is prepared substantially in accordance with the procedure described in Example 1. About 0.30 g of the polypropylene glycol dimethacrylate is added to about 0.70 g of TRIS, about 0.02 g of the hydrophobic monomer isobornylmethacrylate (Sartomer, West Chester, PA), about 0.03 g isopropyl alcohol (JT Baker, Phillipsburg, NJ), and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the previously-described procedure have a Dk of about 85. EXAMPLE 9: About 0.85 g of the polyethyleneglycol dimethacrylate having a molecular weight of about 200 is added to about 0.15 g of TRIS, about 0.10 g of the hydrophobic monomer methyl methacrylate (Aldrich Chemical Co., Milwaukee, Wl) and about 0.05 cc of DAROCUR® 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. EXAMPLE 10: Polypropylene glycol dimethacrylate having a molecular weight of about 4000 is prepared substantially in accordance with the procedure described in Example 1. About 0.20 g of the polypropylene glycol dimethacrylate is added to about 0.70 g of TRIS, about 0.10 g of the hydrophilic monomer N-vinyl pyrrolidone, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. EXAMPLE 11 : Polypropylene glycol dimethacrylate having a molecular weight of about 4000 is prepared substantially in accordance with the procedure described in Example 1. About 0.24 g of the polypropylene glycol dimethacrylate is added to about 0.70 g of TRIS, about 0.02 g of N-vinyl pyrrolidone, 0.04 g isopropyl alcohol (Aldrich Chemical Co.) as solvent, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The material is cured an additional hour at a temperature of 60 °C. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the previously-described procedure have a Dk of about 78. EXAMPLE 12: Polypropylene glycol dimethacrylate having a molecular weight of about 1200 is prepared substantially in accordance with the procedure described in Example 1. About 0.18 g of the polypropylene glycol dimethacrylate is added to about 0.70 g of TRIS, about 0.12 g of the hydrophilic monomer hydroxyethyl methacrylate, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the previously-described procedure have a Dk of about 58. EXAMPLE 13: Polypropyleneglycol dimethacrylate having a molecular weight of about 1200 is prepared substantially in accordance with the procedure described in Example 1. About 0.10 g of the polypropyleneglycol dimethacrylate is added to about 1.0 g of TRIS, about 0.10 g hydroxyethyl methacrylate, about 0.10 g methylethyl ketone solvent, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. EXAMPLE 14: About 0.10 g of the polyethyleneglycol dimethacrylate having a molecular weight of about 600 is added to about 1.0 g of TRIS, about 0.60 g of the hydrophilic monomer dimethylacrylamide (Alcolac, Baltimore, MD), and about 0.05 cc of DAROCUR 1 173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the previously-described procedure have a Dk of about 96. EXAMPLE 15: Polypropylene glycol dimethacrylate having a molecular weight of about 4000 is prepared substantially in accordance with the procedure described in Example 1. About 0.30 g of the polypropylene glycol dimethacrylate is added to about 0.70 g of TRIS, about 0.025 g of the hydrophilic monomer dimethylacrylamide, about 0.025 g isopropyl alcohol solvent, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the previously-described procedure have a Dk of about 98. EXAMPLE 16: About 0.15 g of polyethyleneglycol dimethacrylate having a molecular weight of about 200 is added to about 0.85 g of TRIS, about 0.10 g methylethyl ketone solvent, and about 0.05 cc of DAROCUR 1 173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. EXAMPLE 17: Polypropylene glycol dimethacrylate having a molecular weight of about 1200 is prepared substantially in accordance with the procedure described in Example 1. About 0.30 g of the polypropylene glycol dimethacrylate is added to about 1.0 g of TRIS, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. EXAMPLE 18: About 0.40 g of polytetramethyleneglycol dimethacrylate having a molecular weight of about 1000 is added to about 1.40 g of TRIS, about 0.40 g of dimethylacrylamide, about 0.10 g isopropyl alcohol solvent, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. An additional curing is performed at about 60 °C for about an hour. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the previously-described procedure have a Dk of about 47. EXAMPLE 19: Polypropyleneglycol dimethacrylate having a molecular weight of about 4000 is prepared substantially in accordance with the procedure described in Example 1. About 0.26 g of the polypropyleneglycol dimethacrylate 4000 is added to about 0.040 g poly¬ ethyleneglycol dimethacrylate having a molecular weight of about 600, about 0.70 g of TRIS, about 0.02 g isopropyl alcohol solvent, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the previously-described procedure have a Dk of about 52. EXAMPLE 20: Polypropylene glycol dimethacrylate having a molecular weight of about 4000 is prepared substantially in accordance with the procedure described in Example 1. About 3.0 g of the polypropylene glycol dimethacrylate is added to about 7.0 g of TRIS, about 0.05 g isopropyl alcohol solvent, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. An additional curing is performed at about 60 °C for about an hour. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the previously-described procedure have a Dk of about 58. EXAMPLE 21 : About 0.85 g of polyethylene glycol dimethacrylate having a molecular weight of about 400 is added to about 0.15 g of TRIS, about 0.10 g of the hydrophobic monomer methyl methacrylate, about 0.05 g of methyl ethyl ketone, and about 0.05 cc of DAROCUR 1 173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. EXAMPLE 22: Polypropylene glycol dimethacrylate having a molecular weight of about 4000 is prepared substantially in accordance with the procedure described in Example 1. About 0.30 g of the polypropylene glycol dimethacrylate is added to about 0.70 g of TRIS, about 0.05 g isopropyl alcohol solvent, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. An additional curing is performed at about 60 °C for about an hour. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the previously-described procedure have a Dk of about 93. EXAMPLE 23: About 0.30 g of polyethylene glycol dimethacrylate having a molecular weight of about 200 is added to about 1.0 g of TRIS, about 0.10 g of the hydrophobic monomer methyl methacrylate, about 0.30 g of the hydrophilic monomer dimethylacryl¬ amide, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. EXAMPLE 24: Polypropylene glycol dimethacrylate having a molecular weight of about 4000 is prepared substantially in accordance with the procedure described in Example 1. About 0.18 g of the polypropylene glycol dimethacrylate is added to about 0.70 g of TRIS, about 0.02 g of the hydrophilic monomer hydroxyethyl methacrylate, about 0.10 g of the hydrophilic monomer dimethylacrylamide, and about 0.05 cc of DAROCUR 1173 initiator. The resulting solution is mixed thoroughly and transferred into polypropylene double-sided contact lens molds. The solution is cured in a nitrogen atmosphere by applying UV light for a period of about three hours. The resultant contact lens is removed from the mold and hydrated. Fully hydrated contact lenses prepared substantially in accordance with the previously-described procedure have a Dk of about 32. Table II summarizes the oxygen permeability results described in Examples 5-24. •TABLE Example Monomers Dk 5 0.59 g PPG 4000, 0.70 g TRIS, 0.01 g HFIM 87 6 0.29 g PPG 4000, 0.70 g TRIS, 0.01 g HFIM 88 7 0.28 g PPG 4000, 0.70 g TRIS, 0.02 g HFIM 85 8 0.30 g PPG 4000, 0.70 g TRIS, 0.02 g HFIM 85 1 1 0.24 g PPG 4000, 0.70 g TRIS, 0.02 g NVP 78 12 0.18 g PPG 1200, 0.70 g TRIS, 0.12 g HEMA 58 14 0.10 g PEG 600, 1.0 g TRIS, 0.60 g DMA 96 15 0.30 g PPG 4000, 0.70 g TRIS, 0.025 g DMA 98 18 0.40 g PTG 1000, 1.40 g TRIS, 0.40 g DMA 47 19 0.26 g PPG 4000, 0.04 g PEG 600, 0.70 g TRIS 52 20 3.0 g PPG 4000, 7.0 g TRIS 58 22 0.30 g PPG 4000, 0.70 g TRIS 93 24 0.18 g PPG 4000, 0.70 g TRIS 32 0.02 g HEMA, 0.01 g DMA Examples 5-24 illustrate variations in formulations which may be achieved in accordance with the present invention. Persons having ordinary skill in the art of hydrophilic contact lens fabrication will be capable of formulating numerous other compositions without departing from the scope of the present invention. The invention has been described in detail, with reference to certain preferred embodiments, in order to enable the reader to practice the invention without undue experimentation. However, a person having ordinary skill in the art will readily recognize that many of the previous components and parameters may be varied or modified to a certain extent without departing from the scope and spirit of the invention. Furthermore, titles, headings, or the like are provided to enhance the reader's comprehension of this document, and should not be read as limiting the scope of the present invention. Accordingly, the intellectual property rights to this invention are defined only by the following claims.

Claims: CLAIMS That which is claimed is: 1. A copolymer having high oxygen permeability, ocular biocompatibility, and visual clarity, said copolymer being formed from monomers comprising: (a) 50 to 95 percent by weight vinylic reactive silicone having up to 20 silicon atoms; and (b) 5 to 50 percent by weight divinylic polyalkylene glycol, wherein said copolymer is formed in the substantial absence of additional cross- linking agents. 2. A copolymer of claim 1 , wherein said vinylic reactive silicone has less than 10 silicon atoms. 3. A copolymer of claim 1 , wherein said vinylic reactive silicone has less than 7 silicon atoms. 4. A copolymer of claim 3, wherein said vinylic reactive silicone is selected from the group consisting of 3-methacryloxypropyl tris(trimethylsiloxy) silane; 3-methacryloxypropyl- bis(trimethylsiloxy)methylsilane; 3-methacryloxypropyl-pentamethyldisiloxane; and mixtures thereof. 5. A copolymer of claim 4, wherein said vinylic reactive silicone is 3-methacryloxypropyl tris(trimethylsiloxy) silane (TRIS). 6. A copolymer of claim 1 , wherein said divinylic polyalkylene glycol is selected from the group consisting of dimethacrylates of polyethylene glycols, dimethacrylates of polypropylene glycols, distyrenic-capped polyethylene glycols, distyrenic-capped polypropylene glycols, dimethacrylates of tetramethylene glycol and combinations thereof. 7. A copolymer of claim 6, wherein said divinylic polyalkylene glycol is a polypropylene glycol dimethacrylate. 8. A copolymer of claim 6, wherein said divinylic polyalkylene glycol has a weight average molecular weight of 425 to 4000. 9. A copolymer of claim 1, comprising (a) 50 to 95 percent by weight vinylic reactive silicone having up to 20 silicon atoms; (b) 5 to 49 percent by weight divinylic polyalkylene glycol, and 1 to 40 percent by weight of a hydrophilic monomer. 10. A copolymer of claim 9, wherein said hydrophilic monomer is selected from the group consisting of dimethyl acrylamide, 2-hydroxyethyl methacrylate, N-vinyl pyrrolidone, monomethacrylated polyethylene glycols, monomethacrylated polypropylene glycols, and mixtures thereof. 11. A copolymer of claim 1 , comprising (a) 50 to 95 percent by weight vinylic reactive silicone having up to 20 silicon atoms; (b) 5 to 49 percent by weight divinylic polyalkylene glycol, and 1 to 40 percent by weight of a hydrophobic monomer. 12. A copolymer of claim 11 , wherein said hydrophobic monomer is selected from the group consisting of methyl methacrylate, vinylic-reactive fluorinated monomers, styrenic monomers, isobornyl methacrylate, and mixtures thereof. 13. A copolymer of claim 1 , comprising 60 to 80 weight percent of said vinylic silicone and 20 to 40 weight percent of said divinylic polyalkylene glycol. 14. A hydrophilic contact lens formed from monomers comprising: (a) 50 to 95 percent by weight vinylic reactive silicone having up to 20 silicon atoms; and (b) 5 to 50 percent by weight divinylic polyalkylene glycol, wherein said contact lens is formed in the substantial absence of additional cross- linking agents. 15. A contact lens of claim 14, formed from monomers comprising: (a) 50 to 95 percent by weight 3-methacryloxypropyl tris(trimethylsiloxy) silane; and (b) 5 to 50 percent by weight polypropyleneglycol dimethacrylate. 16. A contact lens of claim 14, consisting essentially of: (a) 50 to 95 weight percent vinylic reactive silicone having up to 20 silicon atoms; (b) 5 to 49 weight percent divinylic polyalkylene glycol; and (c) 1 to 40 weight percent hydrophilicity modifier. 17. A process for making a soft contact lens in the substantial absence of added cross- linking agents, comprising the steps of: (a) contacting a vinylic reactive silicone having up to 20 silicon atoms with a divinylic polyalkylene glycol in the substantial absence of additional cross-linking agents, thereby forming a prepolymerization mixture; (b) placing said prepolymerization mixture and a polymerization initiator in a contact lens mold under conditions sufficient to cause copolymerization of the polyalkylene glycol with the silicone in the substantial absence of additional cross-linking agents; and (c) copolymerizing said polyalkylene glycol and said silicone and allowing said copolymerization to proceed in the substantial absence of cross-linking agents for a period sufficient to yield a contact lens. 18. A process of claim 17, in which said vinylic reactive silicone includes less than 10 silicon atoms. 19. A process of claim 18, in which said vinylic reactive silicone includes less than 7 silicon atoms. 20. A process of claim 19, in which said vinyl reactive silicone is selected from the group consisting of 3-methacryloxypropyl tris(trimethylsiloxy) silane; 3-methacryloxypropyl- bis(trimethylsiloxy)methylsilane; and 3-methacryloxypropyl-pentamethyldisiloxane and mixtures thereof, and said polyalkylene glycol is selected from the group consisting of dimethacrylates of polyethylene glycols, dimethacrylates of polypropylene glycols, distyrenic-capped polyethylene glycols, distyrenic-capped polypropylene glycols, dimethacrylates of tetramethylene glycol and combinations thereof. 21. A process of claim 20, in which said vinyl reactive silicone is 3-methacryloxypropyl tris(trimethylsiloxy) silane (TRIS) and said polyalkylene glycol is polypropylene glycol. 22. A process of claim 17, in which said copolymerization product comprises: (a) 50 to 95 percent by weight vinylic reactive silicone having up to 10 silicon atoms; and (b) 5 to 50 percent by weight divinylic polyalkylene glycol. 23. A process of claim 17, further comprising the step of adding a hydrophilic or hydrophobic monomer to said prepolymerization mixture in order to modify the hydrophilic nature of said contact lens.

Inventors: ALLEN CHERYL RETTER, ROBERTSON JAMES RICHARD, ALLEN, CHERYL, RETTER, ROBERTSON, JAMES, RICHARD
Applicants: ALLEN CHERYL RETTER, CIBA GEIGY AG, ROBERTSON JAMES RICHARD, ALLEN, CHERYL, RETTER, CIBA-GEIGY AG, ROBERTSON, JAMES, RICHARD
Application year: 1995
Main classification: G02B1
IPC codes: B29D11, C08F212, C08F222, C08F230, C08F290, G02B1, G02C7