JP2013538138A - 眼科学デバイス成型用金型及び関連する方法 - Google Patents
眼科学デバイス成型用金型及び関連する方法 Download PDFInfo
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- JP2013538138A JP2013538138A JP2013522296A JP2013522296A JP2013538138A JP 2013538138 A JP2013538138 A JP 2013538138A JP 2013522296 A JP2013522296 A JP 2013522296A JP 2013522296 A JP2013522296 A JP 2013522296A JP 2013538138 A JP2013538138 A JP 2013538138A
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Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Health & Medical Sciences (AREA)
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- Physics & Mathematics (AREA)
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Abstract
【選択図】なし
Description
線型方程式としてのオウエンス-ベント-ラベル-ケーベルの式は、以下の通りである:
約160℃〜約250℃なる範囲の溶融温度;
約160℃〜約250℃なる範囲のバレル温度;
約30℃〜約70℃なる範囲のスロート温度;
約30℃〜約95℃なる範囲の金型温度;
約1秒〜約5秒なる範囲の滞留時間;
約50mm/秒〜約250mm/秒なる範囲の射出速度;
約100mm/秒〜約300mm/秒なる範囲の可塑化速度;
約5〜約18MPa(約50〜約180bar)なる範囲の射出成型圧力;
約1〜約20MPa(約10〜約200bar)なる範囲の保持圧力;
約0.5〜約2.5MPa(約5〜約25bar)なる範囲の背圧。
104・・第一のポリマーを使用する段階
106・・第二のポリマーを準備する段階
108・・第二のポリマーを使用する段階
110・・成型面全体の生成段階
112・・重合性組成物配置段階
114・・金型アセンブリー製造段階
116・・ポリマー製デバイス本体を製造する(硬化)段階
118・・レンズ本体分離段階
120・・洗浄段階
122・・デバイス包装段階
124・・検査段階
126・・随意の段階
202・・要素(第一のポリマー)
204・・要素(成型面の第一部分)
206・・要素(第二のポリマー)
208・・要素(成型面の第一部分)
210・・要素(成型面全体)
212・・要素(重合性組成物)
214・・金型アセンブリー
216、218・・要素(デバイス本体)
220・・レンズ本体
222、226・・包装眼科学デバイス製品
224・・包装され、検査された本体
401・・ループ
402・・リング
3A、3B、3C・・マトリックスデザイン
300A、300B、300C・・(マトリックスの外側周辺部)
4A、4B・・マトリックス
Claims (20)
- 眼科学デバイスの製造方法であって、以下の工程、
(a) 第一のポリマーを準備する工程、
(b) 該第一のポリマーを使用して、眼科学デバイスの前面又は後部面を流延成形するように形作られた、成型面の第一部分を生成する工程、
(c) 第二のポリマーを準備する工程、
(d) 該第二のポリマーを使用して、眼科学デバイスの前面又は後部面を流延成形するように形作られた、成型面の第二部分を生成する工程であって、該第一部分及び該第二部分は、一緒に結合された際に、眼科学デバイスの前面又は後部面全体を成形するように形作られた、成型面全体を生成する工程、
(e) 少なくとも1種の親水性モノマーを含む重合性組成物を、該成型面全体と直接接触した状態に置く工程、及び
(f) 該成型面全体と直接接触した状態にある該重合性組成物を硬化して、ポリマー製眼科学デバイス本体を含む重合反応生成物を生成する工程、
を含むことを特徴とする、前記眼科学デバイスの製造方法。 - 前記第一ポリマーが、エチレン-ビニルアルコールコポリマーではない、少なくとも1種のビニルアルコールコポリマーを含む、請求項1記載の方法。
- 前記第一ポリマーが、ニチゴG-ポリマーを含む、請求項1又は2記載の方法。
- 前記第二ポリマーが、ポリプロピレンを含む、請求項1〜3の何れか1項に記載の方法。
- 前記第一のポリマーを使用して、前記成型面の第一部分を形成する前記工程が、該第一のポリマーを射出成形する工程を含む、請求項1〜4の何れか1項に記載の方法。
- 前記第一のポリマーを射出成形する工程が、約180℃〜約250℃なる範囲の溶融温度、約180℃〜約250℃なる範囲のバレル温度、約30℃〜約70℃なる範囲のスロート温度、約30℃〜約95℃なる範囲の金型温度、約1秒〜約5秒なる範囲の滞留時間、約50mm/秒〜約250mm/秒なる範囲の射出速度、約100mm/秒〜約300mm/秒なる範囲の可塑化速度、約5〜約18MPa(約50〜約180bar)なる範囲の射出成型圧力、約1〜約20MPa(約10〜約200bar)なる範囲の保持圧力、約0.5〜約2.5MPa(約5〜約25bar)なる範囲の背圧、及びこれらの任意の組合せからなる群から選択される、プロセス設定を使用する、請求項5記載の方法。
- 前記第一のポリマーを使用して前記成型面の第一部分を形成する前記工程が、該第一のポリマーを旋盤処理する工程を含む、請求項1〜6の何れか1項に記載の方法。
- 前記第一のポリマーを使用して前記成型面の第一部分を形成する前記工程が、該第一のポリマーのマトリックスを生成する工程を含む、請求項1〜7の何れか1項に記載の方法。
- 前記方法が、更に、前記マトリックスと前記成型面の第二部分とを結合して、前記成型面全体を生成した後、前記重合性組成物を配置して、該成型面全体と直接接触させる工程を含む、請求項8記載の方法。
- 前記第一のポリマーを使用して前記成型面の第一部分を形成する前記工程が、該第一のポリマーを、前記第二のポリマーで作られ、予備成形された成型面上に直接適用する工程を含む、請求項1〜9の何れか1項に記載の方法。
- 前記第一のポリマーを前記予備成形された成型面上に直接適用する前記工程が、前記ビニルアルコールを流延して、前記第二のポリマーで作られた前記成型面の第二部分を含む、予備成形された金型部材とする工程を含む、請求項10記載の方法。
- 前記方法が、更に、前記成型面の第一部分及び第二部分両者から、前記ポリマー製眼科学デバイス本体を離型する工程を含み、かつ該ポリマー製眼科学デバイス本体が、該成型面の第一部分から離型される前に、該デバイス本体が、該成型面の第二部分から離型される、請求項1〜11の何れか1項に記載の方法。
- 前記方法が、更に、前記ポリマー製眼科学デバイス本体又は前記成型面の第二部分を液体と接触させる工程を含まない方法を利用して、該デバイス本体を少なくとも該成型面の第二部分から離型する工程をも含む、請求項1〜12の何れか1項に記載の方法。
- 前記方法が、更に、前記ポリマー製眼科学デバイス本体及び前記成型面の第一部分を液体と接触させることによって、少なくとも該成型面の第一部分から、該デバイス本体を離型する工程をも含む、請求項1〜13の何れか1項に記載の方法。
- 前記成型面の第一部分と前記液体との接触が、該成型面の第一部分を少なくとも部分的に溶解している該液体をもたらす、請求項14記載の方法。
- 前記重合性組成物が、少なくとも1種のケイ素-含有モノマーを含み、かつ前記ポリマー製眼科学デバイス本体が、シリコーンヒドロゲル眼科学デバイス本体を含む、請求項1〜15の何れか1項に記載の方法。
- 前記成型面全体が、コンタクトレンズの後部面を成形するように形作られた全成型面を含み、かつ前記ポリマー製眼科学デバイス本体が、ポリマー製コンタクトレンズ本体を含む、請求項1〜16の何れか1項に記載の方法。
- 前記成型面の第一部分が、前記デバイスの表面上に少なくとも一つのチャンネルを形成するように形作られている、請求項1〜17の何れか1項に記載の方法。
- 前記成型面の第一部分が、前記デバイスの少なくとも一つの表面から、該デバイスの本体内に伸びている、少なくとも一つのチャンネルを形成するように形作られている、請求項1〜17の何れか1項に記載の方法。
- 眼科学コンタクトレンズ成型用金型部材であって、以下の部品、
(a) 第一のポリマーで作成された成型面の第一部分であって、該第一部分が、コンタクトレンズ表面の第一の領域を流延成形するように形作られている第一部分、及び
(b) 第二のポリマーで作成された成型面の第二部分であって、該第二の部分が、該表面の第二の領域を流延成形するように形作られている第二部分、
を含み、該第二の部分が、該第一の部分との組合せで、成型面全体を形成するように形作られており、かつ該第一の部分と該第二の部分との組合せが、コンタクトレンズの全表面を流延成形するように形作られていることを特徴とする、前記眼科学コンタクトレンズ成型用金型部材。
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