Ophthalmic Device Molds Formed From Vinyl Alcohol Copolymer, Ophthalmic Devices Molded Therein, And Related Methods
First Claim
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1. A method of manufacturing an ophthalmic device, comprising:
- (a) providing at least one vinyl alcohol copolymer,(b) using the at least one vinyl alcohol copolymer to form at least one of a first mold member and a second mold member, the at least one of the first mold member and the second mold member comprising a device-forming molding surface having a static sessile drop contact angle less than 60 degrees and which is free of a plasma treatment, wherein the first mold member comprises a molding surface configured to mold an anterior surface of an ophthalmic device and the second mold member comprises a molding surface configured to mold a posterior surface of an ophthalmic device, and the first mold member and the second mold member are configured to form an ophthalmic device-shaped cavity therebetween when combined as a mold assembly;
(c) placing a polymerizable composition comprising at least one hydrophilic monomer in the first mold member or the second mold member;
(d) assembling the mold assembly by contacting the first mold member and the second mold member so as to form the ophthalmic device-shaped cavity therebetween with the polymerizable composition contained in the ophthalmic device-shaped cavity of the mold assembly; and
(e) curing the polymerizable composition in the mold assembly to form a cast-molded polymerized reaction product in the ophthalmic device-shaped cavity of the mold assembly, the polymerized reaction product comprising a polymeric ophthalmic device body.
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Abstract
Ophthalmic device molds made from at least one vinyl alcohol copolymer and having a static sessile drop contact angle of less than 70 degrees, ophthalmic devices such as ocular inserts and contact lenses and including silicone hydrogel devices formed using these molds, and related methods are described. The methods of manufacturing ophthalmic devices can use dry or wet demolding processes, or dry or wet delensing processes.
20 Citations
20 Claims
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1. A method of manufacturing an ophthalmic device, comprising:
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(a) providing at least one vinyl alcohol copolymer, (b) using the at least one vinyl alcohol copolymer to form at least one of a first mold member and a second mold member, the at least one of the first mold member and the second mold member comprising a device-forming molding surface having a static sessile drop contact angle less than 60 degrees and which is free of a plasma treatment, wherein the first mold member comprises a molding surface configured to mold an anterior surface of an ophthalmic device and the second mold member comprises a molding surface configured to mold a posterior surface of an ophthalmic device, and the first mold member and the second mold member are configured to form an ophthalmic device-shaped cavity therebetween when combined as a mold assembly; (c) placing a polymerizable composition comprising at least one hydrophilic monomer in the first mold member or the second mold member; (d) assembling the mold assembly by contacting the first mold member and the second mold member so as to form the ophthalmic device-shaped cavity therebetween with the polymerizable composition contained in the ophthalmic device-shaped cavity of the mold assembly; and (e) curing the polymerizable composition in the mold assembly to form a cast-molded polymerized reaction product in the ophthalmic device-shaped cavity of the mold assembly, the polymerized reaction product comprising a polymeric ophthalmic device body. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. An ophthalmic device body, comprising:
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a cast-molded polymerized device body comprising the reaction product of a polymerizable composition, the polymerizable composition comprising at least one hydrophilic monomer; wherein the device body is cast-molded in a mold assembly comprising a first mold member and a second mold member, the at least one of the first mold member and the second mold member being formed from at least one vinyl alcohol copolymer, and comprising a device-forming molding surface having a static sessile drop contact angle less than 60 degrees which is free of a plasma treatment. - View Dependent Claims (16, 17, 18, 19)
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20. A mold member for cast molding an ophthalmic device body, comprising:
a mold member comprising a device-forming molding surface and a non-molding region, wherein at least the device-forming molding surface of the mold member comprises at least vinyl alcohol copolymer, has a static sessile drop contact angle less than 60 degrees, and is free of a plasma treatment.
Specification