CA2435808A1 - Shape memory polymer or alloy ophthalmic lens mold and methods of forming ophthalmic products - Google Patents

Shape memory polymer or alloy ophthalmic lens mold and methods of forming ophthalmic products Download PDF

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Publication number
CA2435808A1
CA2435808A1 CA002435808A CA2435808A CA2435808A1 CA 2435808 A1 CA2435808 A1 CA 2435808A1 CA 002435808 A CA002435808 A CA 002435808A CA 2435808 A CA2435808 A CA 2435808A CA 2435808 A1 CA2435808 A1 CA 2435808A1
Authority
CA
Canada
Prior art keywords
mold
shape memory
memory polymer
accordance
temperature
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002435808A
Other languages
French (fr)
Other versions
CA2435808C (en
Inventor
Gregory J. Hofmann
Kenneth W. Foley
Thomas R. Rooney
Patrick Hood
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Johnson and Johnson Vision Care Inc
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=23004079&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=CA2435808(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Individual filed Critical Individual
Publication of CA2435808A1 publication Critical patent/CA2435808A1/en
Application granted granted Critical
Publication of CA2435808C publication Critical patent/CA2435808C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/0048—Moulds for lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C61/00—Shaping by liberation of internal stresses; Making preforms having internal stresses; Apparatus therefor
    • B29C61/06—Making preforms having internal stresses, e.g. plastic memory
    • B29C61/0608—Making preforms having internal stresses, e.g. plastic memory characterised by the configuration or structure of the preforms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00038—Production of contact lenses
    • B29D11/00125—Auxiliary operations, e.g. removing oxygen from the mould, conveying moulds from a storage to the production line in an inert atmosphere
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00038—Production of contact lenses
    • B29D11/00125—Auxiliary operations, e.g. removing oxygen from the mould, conveying moulds from a storage to the production line in an inert atmosphere
    • B29D11/00192—Demoulding, e.g. separating lenses from mould halves
    • B29D11/00221—Demoulding, e.g. separating lenses from mould halves using prying means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00432—Auxiliary operations, e.g. machines for filling the moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/0048—Moulds for lenses
    • B29D11/00548—Moulds for lenses with surfaces formed by films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/0048—Moulds for lenses
    • B29D11/00557—Moulds for lenses with deformable mould walls, e.g. to make lenses with different shapes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F212/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring
    • C08F212/02—Monomers containing only one unsaturated aliphatic radical
    • C08F212/04—Monomers containing only one unsaturated aliphatic radical containing one ring
    • C08F212/06—Hydrocarbons
    • C08F212/08—Styrene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C61/00—Shaping by liberation of internal stresses; Making preforms having internal stresses; Apparatus therefor
    • B29C61/06—Making preforms having internal stresses, e.g. plastic memory
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/10—Thermosetting resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0072—Roughness, e.g. anti-slip
    • B29K2995/0073—Roughness, e.g. anti-slip smooth

Landscapes

  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Ophthalmology & Optometry (AREA)
  • Chemical & Material Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Medicinal Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Prostheses (AREA)

Abstract

A shape memory polymer contact lens mold is formed from a sheet of a shape memory polymer in a press, an agile tool or by an agile tool formed by an inert gas at a temperature at or above the glass transition temperature whic h is thereupon cooled to below the glass transition temperature and removed therefrom.

Claims (26)

1. An ophthalmic mold comprising a shape memory polymer or shape memory alloy.
2. A mold in accordance with Claim 1 wherein said shape memory polymer is selected from the group consisting of norbornene homopolymers, copolymers of norbornene and alkylated imides, copolymers of norbornene and cyanoimides, copolymers of norbornene and alkoxylated imides, copolymers of norbornene and mono- or diesterified imides, copolymers of norbornene and a carboxylic acid derivative, a copolymer of norbornene and dimethane octahydronaphthalate and a copolymer of styrene and a vinyl compound.
3. A mold in accordance with Claim 2 wherein said shape memory polymer is a thermosetting resin.
4. A mold in accordance with Claim 3 wherein said SMP is a radiation cured resin.
5. A mold in accordance with Claim 3 wherein said thermosetting shape memory polymer is a copolymer of styrene and a vinyl compound.
6. A mold in accordance with Claim 1 comprising a first member and a second member.
7. A mold in accordance with claim 6 wherein said mold is prepared in a press and said second member of said mold is formed in a shape of a base curve element and said first member is formed in a shape of a front curve element.
8. A mold in accordance with Claim 7 wherein said press includes a core element which interacts with said base curve element or said front curve element.
9. A mold in accordance with Claim 8 wherein said base curve element and said front curve element are formed of a metal and wherein said base curve and said front curve elements have an optical forming surface whose root mean square surface roughness is no more than about 20 nanometers.
10. A mold in accordance with Claim 7 wherein said core element is provided by gas pressure.
11. A mold in accordance with Claim 1 wherein a mold half of said shape memory polymer mold is prepared in said press by the steps which comprise:
a) placing a preform of a shape memory polymer between a front curve element or a base curve element and a core element;
b) heating said preform to a temperature at or above the glass transition temperature but below the decomposition temperature of said shape memory polymer;
c) providing a pressure sufficient to cause said shape memory polymer sheet to assume a shape of said front curve or base curve element;
d) reducing the temperature of said formed shape memory polymer to below said glass transition temperature;
e) removing said formed shape memory polymer from said press.
12. A mold in accordance with Claim 11 wherein said temperature in said step d) is reduced to ambient.
13. A mold in accordance with Claim 11 wherein said preform is a sheet of said shape memory polymer is disposed in a holder prior to said step (a) and said formed shape memory polymer is removed from said holder subsequent to said step e).
14. A mold in accordance with Claim 1 further comprising one or more mold members wherein at least one mold member is prepared in an agile tool, comprising adjustment means that are used to shape said mold member.
15. A mold in accordance with Claim 14 wherein said adjustment means is a plurality or an array of concentric tubes, and said agile tool further comprises a deformable molding surface.
16. A mold in accordance with Claim 14 wherein said adjustment means is a plurality or an array of pins.
17. A mold in accordance with Claim 14 wherein said adjustment means is an array of heaters.
18. A mold in accordance with Claim 14 wherein said shape memory polymer halves are prepared in said agile tool by the steps which comprise:
a) contacting a sheet of a shape memory polymer between deformable molding surface, whose shape is defined by adjustment means, and a core element under a pressure sufficient to cause said shape memory polymer sheet to assume a shape of said front curve or base curve actuated surface at a temperature at or above the glass transition temperature but below the decomposition temperature of said shape memory polymer;
b) reducing the temperature of said formed shape memory polymer to below said glass transition temperature;
c) moving said core element out of contact with said sheet of said shape memory polymer; and d) removing a mold formed shape memory polymer from said agile tool.
19. A mold in accordance with Claim 18 wherein said sheet of said shape memory polymer is disposed in a holder prior to said step (a) and said formed shape memory polymer is removed from said holder subsequent to said step (d).
20. A mold in accordance with Claim 6, wherein at least one surface of at least one mold member is formed by gas pressure that presses the surface opposite said one surface against a surface of a press or agile tool.
21. A mold in accordance with Claim 20 wherein said surface of said agile tool is formed by a plurality of concentric tubes.
22. A mold in accordance with Claim 1 wherein said mold is prepared by the steps which comprise:
a) disposing a sheet of a shape memory polymer upon an adjustment means, set to define a predetermined shape, said adjustment means being in a desired shape;
b) elevating the temperature of said sheet of said shape memory polymer to at least the glass transition temperature but below the decomposition temperature;
c) emitting a stream of gas at said sheet of said shape memory polymer at a pressure sufficient to cause a sheet of said shape memory polymer to form a shape of said adjustment means;
d) reducing the temperature of said formed shape memory polymer to below said glass transition temperature e) removing said formed shape memory polymer from atop said adjustment means.
23. A mold in accordance with Claim 26 wherein said stream of temperature in said step (d) is reduced to ambient.
24. A mold in accordance with Claim 22 including the step of creating a vacuum concurrent with step (c).
25. A mold in accordance with claim 1 that further comprises intrinsic actuators.
26. A mold in accordance with claim 25 wherein said mold is prepared by the steps which comprise:
a) compressing a preform with projections on one surface of said preform;
b) actuating selected intrinsic actuators by heating said individual intrinsic actuators above the Tg of said intrinsic actuators, and c) cooling said intrinsic actuators.
CA2435808A 2001-01-24 2002-01-24 Shape memory polymer or alloy ophthalmic lens mold and methods of forming ophthalmic products Expired - Fee Related CA2435808C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US26398601P 2001-01-24 2001-01-24
US60/263,986 2001-01-24
PCT/US2002/002203 WO2002059169A1 (en) 2001-01-24 2002-01-24 Shape memory polymer or alloy ophthalmic lens mold and methods of forming ophthalmic products

Publications (2)

Publication Number Publication Date
CA2435808A1 true CA2435808A1 (en) 2002-08-01
CA2435808C CA2435808C (en) 2011-01-04

Family

ID=23004079

Family Applications (2)

Application Number Title Priority Date Filing Date
CA002435809A Abandoned CA2435809A1 (en) 2001-01-24 2002-01-24 Shape memory styrene copolymer
CA2435808A Expired - Fee Related CA2435808C (en) 2001-01-24 2002-01-24 Shape memory polymer or alloy ophthalmic lens mold and methods of forming ophthalmic products

Family Applications Before (1)

Application Number Title Priority Date Filing Date
CA002435809A Abandoned CA2435809A1 (en) 2001-01-24 2002-01-24 Shape memory styrene copolymer

Country Status (11)

Country Link
US (1) US6759481B2 (en)
EP (2) EP1373340B1 (en)
JP (2) JP2004530573A (en)
KR (2) KR100874602B1 (en)
CN (2) CN1275991C (en)
AU (2) AU2002243678B2 (en)
BR (2) BR0206691B1 (en)
CA (2) CA2435809A1 (en)
DE (2) DE60206739T2 (en)
HK (2) HK1058681A1 (en)
WO (2) WO2002059170A1 (en)

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