Process for manufacture of a porous polymer from a mixture

• US 6,015,609 A
• Filed: 05/10/1999
• Issued: 01/18/2000
• Est. Priority Date: 04/04/1996
• Status: Expired due to Term

• Current Assignee: Commonwealth Scientific & Industrial Research Organisation (Commonwealth Of Australia As Represented By Department Of Industry, Innovation, Climate Change, Science, Research And Tertiary Education), Novartis Ag
• Original Assignee: Commonwealth Scientific & Industrial Research Organisation (Commonwealth Of Australia As Represented By Department Of Industry, Innovation, Climate Change, Science, Research And Tertiary Education), Novartis Ag
• Inventors: Chaouk, Hassan, Meijs, Gordon Francis, Laycock, Bronwyn Glenice
• Primary Examiner(s): Acquah, Samuel A.
• Application Number:
  US09/155,548
• Time in Patent Office: 253 Days
• Field of Search: 528/486, 528/491, 528/492, 528/493, 528/494, 528/495, 528/496, 528/499, 524/81, 524/186, 524/205, 524/220, 524/366, 428/98, 428/159, 428/221, 428/304.4, 428/308.4
• US Class Current: 428/308.4
• CPC Class Codes: B01D 2323/18 Pore-control agents or pore formers
• CPC Class Codes: B01D 2325/02 Details relating to pores or porosity of the membranes
• CPC Class Codes: B01D 2325/026 Sponge structure
• CPC Class Codes: B01D 2325/0283 Pore size
• CPC Class Codes: B01D 2325/22 Thermal or heat-resistance properties
• CPC Class Codes: B01D 2325/28 Degradation or stability over time
• CPC Class Codes: B01D 2325/30 Chemical resistance
• CPC Class Codes: B01D 67/0006 by chemical reactions in-situ polymerisation, polycondensation, cross-linking or reaction for manufacturing composite membranes B01D69/125
• CPC Class Codes: B01D 67/003 by selective elimination of components, e.g. by leaching
• CPC Class Codes: B01D 71/32 containing fluorine atoms
• CPC Class Codes: C08G 65/007 containing fluorine
• CPC Class Codes: C08J 2371/00 Characterised by the use of polyethers obtained by reactions forming an ether link in the main chain of polyacetals C08J2359/00; of epoxy resins C08J2363/00; of polythioether-ethers C08J2381/02; of polyethersulfones C08J2381/06; Derivatives of such polymers
• CPC Class Codes: C08J 9/286 the liquid phase being a solvent for the monomers but not for the resulting macromolecular composition, i.e. macroporous or macroreticular polymers
• CPC Class Codes: C08L 63/00 Compositions of epoxy resins; Compositions of derivatives of epoxy resins
• CPC Class Codes: C08L 71/02 Polyalkylene oxides
• CPC Class Codes: G02B 1/043 Contact lenses
• CPC Class Codes: Y10T 428/24 Structurally defined web or sheet [e.g., overall dimension, etc.]
• CPC Class Codes: Y10T 428/24504 Component comprises a polymer [e.g., rubber, etc.]
• CPC Class Codes: Y10T 428/249921 Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249958 : Void-containing component is synthetic resin or natural rubbers

Abstract

The present invention is directed to a process for the production of a porous polymer comprising the steps of: i) forming a mixture comprising a polymerizable component and an organic solvent wherein the polymerizable component comprises at least one macromonomer having at least one perfluoropolyether unit; ii) polymerizing said mixture wherein immediately after the polymerization of said mixture at least a substantial proportion of said organic solvent is in the form of a discrete phase and wherein said discrete organic solvent phase forms an interpenetrating network throughout the mixture or is dispersed throughout the mixture; and iii) removing the discrete organic solvent phase.

Claims

1. A process for the production of a porous polymer comprising the steps of:

i) forming a mixture comprising a polymerizable component and an organic solvent wherein the polymerizable component comprises at least one macromonomer having at least one perfluoropolyether unit;

ii) polymerizing said mixture wherein immediately after the polymerization of said mixture at least a substantial proportion of said organic solvent is in the form of a discrete phase and wherein said discrete organic solvent phase forms an interpenetrating network throughout the mixture or is dispersed throughout the mixture; and

iii) removing the discrete organic solvent phase.

2. A process according to claim 1 wherein the organic solvent is a polar solvent.

3. A process according to claim 2 wherein the organic solvent is selected from the group consisting of short chain alcohols, amines, ethers, nitrites, carboxylic acids, ketones, and mixtures thereof.

4. process according to claim 3 wherein the organic solvent is selected from the group consisting of C₁ -C₁₀ -alkanols, C₁ -C₁₀ -amines, C₁ -C₁₀ -nitrites, C₁ -C₁ -carboxylic acids, C₁ -C₁₀ -ketones, and mixtures thereof.

5. A process according to claim 3 wherein the organic solvent is selected from the group consisting of nonfluorinated C₁ -C₁₀ -alkanols, C₁ -C₁₀ -amines, C₁ -C₁₀ -nitrites, C₁ -C₁₀ -carboxylic acids, C₁ -C₁₀ -ketones, and mixtures thereof.

6. A process according to claim 2 wherein the organic solvent is an alcohol of up to 12 carbon atoms.

7. A process according to claim 6 wherein the alcohol is isopropanol.

8. A process according to claim 2 wherein the organic solvent is an ether.

9. A process according to claim 2 wherein the organic polar solvent is used in admixture with a minor proportion of a non-polar solvent or water.

10. A process according to claim 1 wherein the polymerizable mixture comprises a surfactant.

11. A process according to claim 10 wherein the surfactant is a polymerizable surfactant.

12. A porous polymer comprising perfluoropolyether units prepared according to the process described in claim 1.

13. A film or sheet comprising the porous polymer of claim 12.

14. An ophthalmic device comprising the porous polymer of claim 12.

15. A process according to claim 3 wherein the organic polar solvent is used in admixture with a minor proportion of a non-polar solvent or water.

16. A process according to claim 4 wherein the organic polar solvent is used in admixture with a minor proportion of a non-polar solvent or water.

17. A process according to claim 5 wherein the organic polar solvent is used in admixture with a minor proportion of a non-polar solvent or water.

18. A process according to claim 6 wherein the organic solvent is a non-fluorinated alcohol.

19. A process according to claim 2 wherein the organic solvent is diisopropyl ether.