Method for manufacturing contact lens by using mangostin xanthone compound

Abstract

The present invention relates to a method for manufacturing a contact lens by introducing, as an IPN, a mangostin xanthone compound onto the surface of a contact lens. A contact lens is manufactured through: a step of mixing raw materials, homogenizing same, and then injecting same into a mold and thermal polymerizing same so as to prepare a contact lens polymer; a pretreatment step of removing the contact lens polymer from the mold so as to rinse off and remove unreacted materials; a step of soaking the contact lens polymer in an IPN solution containing a mangostin xanthone compound so as to perform IPN coating on the surface of the contact lens polymer; and, after the IPN coating, a post-treatment step of rinsing off and removing unreacted materials.

Description

Method for manufacturing contact lenses using mangosteen xanthone compounds

[0001] The present invention relates to a method for manufacturing a contact lens that provides antibacterial, antiviral, and antioxidant effects as well as ultraviolet ray blocking and blue light blocking effects by introducing a mangosteen xanthone compound to the surface of the contact lens as an IPN.

[0002]

[0003] In general, contact lenses must meet the following requirements: adequate tensile strength, biocompatibility, non-toxicity, optical transparency, refractive index, surface wettability, corneal-compatible water content, swelling ratio, oxygen transmissibility, and flexibility.

[0004] In particular, considering the problems and side effects of ophthalmic diseases caused by long-term wear of contact lenses, the requirement of oxygen transmissibility is very important.

[0005] Therefore, research and development of materials with excellent oxygen permeability are actively being conducted to improve the oxygen permeability of contact lenses, and contact lenses made of silicone hydrogel are currently being manufactured in general.

[0006] Because typical silicone monomers are hydrophobic, the water content of hydrogel lenses manufactured using these monomers is low. Therefore, they are used in polymerization with hydrophilic monomers such as 2-hydroxyethyl methacrylate (HEMA) and are used as contact lens materials. However, because these hydrophobic silicone monomers do not mix with other hydrophilic monomers, the manufactured lenses are cloudy, have low light transmittance, and have poor water content.

[0007] To maintain eye health while wearing contact lenses, contact lenses with excellent wettability, oxygen permeability, and minimal protein and other deposits are necessary. In particular, the need for high-performance contact lenses with biocompatible antibacterial properties to protect eyes from today's air, which is rich in fine dust and other pollutants, is on the rise.

[0008] Meanwhile, contact lenses can cause infectious diseases such as bacterial keratitis due to improper care, and in severe cases, can lead to serious side effects such as corneal ulcers or blindness.

[0009] Bacterial keratitis caused by bacterial infection is frequently caused by contact lenses that come into direct contact with the eye, so the need for the development of contact lenses with antibacterial effects is rapidly increasing.

[0010] To solve these problems, various methods are being attempted both domestically and internationally to reduce the formation of bacterial biofilms in contact lens storage containers and to achieve antibacterial effects. Research is also underway on methods to impart antibacterial properties to contact lens raw materials by adding antibacterial materials to them.

[0011] Meanwhile, xanthone compounds in mangosteen are known to have pharmacological activities such as antioxidant, antibacterial, antihistamine, anti-inflammatory, and antiviral effects, but there have been no cases of application to contact lenses yet.

[0012]

[0013] The present invention was created to solve the above-mentioned problem, and provides a method for manufacturing a contact lens using a mangosteen xanthone compound, which manufactures a contact lens having antibacterial and antiviral effects and antioxidant effects as well as ultraviolet ray blocking and blue light blocking functions by introducing a mangosteen xanthone compound as an IPN to the surface of a contact lens.

[0014] In addition, the present invention provides a method for manufacturing a contact lens using a mangosteen xanthone compound, which can solve the economical problem caused by the large amount of input that occurs when manufacturing a contact lens by copolymerizing the mangosteen xanthone compound with a contact lens material by introducing the mangosteen xanthone compound to the surface of the contact lens as an IPN.

[0015]

[0016] The present invention provides a method for solving the above-described problems, comprising: a step of mixing raw materials to homogenize them, then injecting them into a mold and thermally polymerizing them to manufacture a contact lens polymer; a pretreatment step of removing the contact lens polymer from the mold and washing away unreacted substances; a step of immersing the contact lens polymer in an IPN solution containing a mangosteen xanthone compound to coat the surface of the contact lens polymer with IPN; and a posttreatment step of washing away unreacted substances after the IPN coating, thereby manufacturing a contact lens.

[0017] When the above contact lens polymer is IPN coated, the coating is performed by immersing it in an IPN solution at 80 to 90°C for 30 to 180 minutes.

[0018] Here, the IPN solution is composed of 70 to 85 wt% of ultrapure water (DI water), 3 to 20 wt% of DMA, 0.05 to 1 wt% of AIBN, and 3 to 20 wt% of mangosteen xanthone compound.

[0019] The above contact lens polymer is preferably composed of a mixture of 40 to 50 wt% HEMA, 0.05 to 1 wt% EGDMA, 0.1 to 2 wt% AIBN, 2 to 10 wt% MPC, 20 to 60 wt% DMA, and 5 to 15 wt% PDMS.

[0020] At this time, it is preferable that the mold for manufacturing the contact lens polymer is made of a polyketone material having high dimensional stability and thermal stability.

[0021]

[0022] Contact lenses manufactured by the above method exhibit antibacterial, antiviral and antioxidant effects by introducing mangosteen xanthone compounds as IPNs onto the surface of the contact lenses, and have various functions such as UV blocking and blue light blocking.

[0023]

[0024] Figure 1 is an exemplary diagram of a process for manufacturing a contact lens by introducing a mangosteen xanthone compound according to the present invention into IPN.

[0025] Figure 2 is a graph of light transmittance according to the type of mangosteen according to the present invention.

[0026] Figure 3 is a graph showing the ultraviolet and blue light blocking rate test of contact lenses manufactured by introducing mangosteen (gamma-mangosteen) xanthone extract according to the present invention into IPN.

[0027] Figure 4 is a photograph of an anaerobic fungal and aerobic bacterial culture test to confirm the antibacterial activity of the mangosteen xanthone extract according to the present invention.

[0028] Figure 5 is a graph showing the defect rate according to the initiator content and temperature of the IPN solution according to the present invention.

[0029]

[0030] Hereinafter, a method for manufacturing a contact lens using a mangosteen xanthone compound according to a preferred embodiment of the present invention will be described in detail with reference to the attached drawings.

[0031] As illustrated in FIG. 1, a manufacturing method for manufacturing a contact lens using a mangosteen xanthone compound according to the present invention involves placing raw materials that serve as basic samples of contact lenses into a container, mixing and homogenizing the raw materials, and then injecting them into a mold to thermally polymerize the raw materials to manufacture a contact lens polymer.

[0032] The manufactured contact lens polymer is immersed in an IPN solution containing a mangosteen xanthone compound to coat the surface of the contact lens polymer with IPN.

[0033] Before and after IPN coating, pretreatment and post-treatment steps are performed respectively.

[0034] In the pretreatment step, unreacted substances or impurities from the manufacturing process of the contact lens polymer are washed away, and the contact lens polymer can be washed by ultrasonic treatment while being placed in an ethanol solution, as in a known washing method.

[0035] In the post-processing step, unreacted substances such as monomers and impurities are washed away after IPN coating.

[0036] After cleaning is completed through post-processing of contact lenses, an extract test is conducted to check whether unreacted monomers or impurities have been washed away.

[0037] An interpenetrating polymer network (IPN) is a type of polymer blend that combines two or more networks, where the polymer chains within one network are physically intertwined with those within another, making separation of the individual networks difficult. IPNs exhibit novel physicochemical properties, and these network properties can vary depending on the type and concentration of the polymers, the cross-linking method, and the overall process used to prepare them.

[0038] In the present invention, since the IPN solution contains a mangosteen xanthone compound, the contact lens polymer coated with IPN has antibacterial properties as well as antiviral and antioxidant effects, and also has ultraviolet ray blocking and blue light blocking functions.

[0039] There are about 50 types of xanthones in the peel of mangosteen, and the xanthone compounds of mangosteen are known to have pharmacological activities such as antioxidant, antibacterial, antihistamine, anti-inflammatory, and antiviral effects. The main xanthone compounds of mangosteen are high in alpha-mangostin and gamma-mangostin, and it has been reported that these have excellent antibacterial properties.

[0040] Additionally, mangosteen has antioxidant, antifungal, and antiviral effects, as well as UV and blue light blocking effects.

[0041] When the above contact lens polymer is IPN coated, the coating is performed by immersing it in an IPN solution at 80 to 90°C for 30 to 180 minutes.

[0042] As the IPN coating time increases, the coating thickness gradually increases, but even if it is immersed for more than 180 minutes, it does not have a significant effect.

[0043] In addition, since coating is not smoothly performed below 80℃, the coating thickness is thin and coating must be performed for a long time, making it ineffective. In addition, if coating is performed at a temperature that is too high, such as 90℃ or higher, especially 100℃ or higher, damage increases, increasing the possibility of defects.

[0044] At this time, the IPN solution is composed of 70 to 85 wt% of ultrapure water (DI water), 3 to 20 wt% of DMA, 0.05 to 1 wt% of AIBN, and 3 to 20 wt% of mangosteen xanthone compound.

[0045] The IPN solution is manufactured by adding the mangosteen xanthone compound as a basic raw material to have antibacterial effects and ultraviolet and blue light functions, and further adding DMA as a hydrophilic monomer and AIBN as an initiator.

[0046] The purpose of the hydrophilic monomer is to increase the surface hydrophilicity when introducing IPN to obtain excellent wearing comfort of the contact lens.

[0047] If the above mangosteen xanthone compound is added in an amount less than 3% by weight, it is difficult to expect satisfactory antibacterial properties and UV-blocking and blue light-blocking effects as it is added in too small an amount. If it is added in an amount exceeding 20% ​​by weight, the antibacterial properties are improved and the UV-blocking and blue light-blocking effects are increased, but since there is no significant difference, it is not good in terms of efficiency and is not economical due to increased cost.

[0048] As a hydrophilic monomer, there is another type of hydrophilic monomer, MPC, instead of DMA, but in the case of MPC, there is a problem that white clouding of contact lenses occurs when mixed with mangosteen xanthone compounds during IPN.

[0049] Figure 2 is a graph analyzing the light transmittance according to the type of mangosteen, and it was confirmed that all mangosteens had UV and blue light blocking effects.

[0050] It was shown to block over 90% of UV-B, about 70% of UV-A, and about 25% of blue light, while allowing over 90% of visible light to pass through.

[0051] Figure 3 is a graph showing the ultraviolet and blue light blocking rates of contact lenses manufactured by introducing mangosteen (gamma-mangosteen) xanthone extract into IPN.

[0052] The coating solution concentration of the contact lens was added so that the gamma-mangosteen content was 15% by weight of the total weight.

[0053] The test results showed that it had a significant blocking rate of 83% for UV-B, 72% for UV-A, and 25% for blue light (380-500 nm).

[0054] Figure 4 is a photograph of an anaerobic fungal and aerobic bacterial culture test to confirm the antibacterial activity of a mangosteen xanthone extract. As a comparison group, a general contact lens without a mangosteen xanthone compound added, a contact lens coated with an IPN solution with alpha-mangosteen added, a contact lens coated with an IPN solution with beta-mangosteen added, and a contact lens coated with an IPN solution with gamma-mangosteen added were tested.

[0055] The results of the antibacterial test conducted by culturing anaerobic fungi in SDA and the aerobic bacteria in TSA showed that there was no significant difference between each mango skin and that the antibacterial activity was high.

[0056] Comparatively, in the anaerobic fungal test, contact lenses coated with IPN solution containing beta-mangosteen showed the best antibacterial activity, and in the aerobic bacterial test, contact lenses coated with IPN solution containing gamma-mangosteen showed the best antibacterial activity.

[0057] Figure 5 is a graph showing the failure rate according to the initiator content and temperature of the IPN solution.

[0058] When the initiator content was 0.1 wt% of the total weight and the temperature was 80℃, the defect rate due to staining was higher compared to 100℃ or 120℃, but when the initiator content was 0.4 wt%, the defect rate was the lowest compared to 80℃, and it was found that as the temperature increased, damage increased and the defect rate increased.

[0059] Therefore, it can be confirmed that the higher the initiator content and the lower the temperature, the lower the defect rate.

[0060] In addition, the durability of contact lenses manufactured by introducing mangosteen (gamma-mangosteen) xanthone extract into IPN was tested using cotton swabs.

[0061] As a result of testing the process of touching the surface of the contact lens with a cotton swab more than 10 times, it was confirmed that no pigment was transferred to the ocular joint, and that the durability was better than that of a coating using a general cross-linking technique. In addition, since the polymer matrix is ​​entangled when gamma-mangosteen is IPNed, it is confirmed that the durability is high because it does not separate.

[0062] Meanwhile, when manufacturing contact lenses using mangosteen xanthone compounds, if a contact lens polymer is manufactured using a commonly used mold, a large amount of mangosteen xanthone compounds must be added, which is not economical, and if added to a management solution or packaging solution, only a temporary effect is obtained, so a method for maximizing the effect of mangosteen is needed.

[0063] Molds used in the manufacture of conventional contact lens polymers are generally made of materials such as polypropylene (PP) and polybutylene terephthalate (PBT).

[0064] However, in the present invention, when manufacturing a contact lens by introducing a mangosteen xanthone compound as an IPN, the peripheral curve (zone), which is the outermost edge portion that maintains the structural shape of the contact lens, must be manufactured thinly and precisely. However, when using PP and PBT materials, the deviation in curve and degree, etc. is high, making it difficult to produce the contact lens.

[0065] When a contact lens polymer was manufactured using a mold made of commonly used PP or PBT material and then coated by immersing it in an IPN solution containing a mangosteen xanthone compound, a problem occurred in which the peripheral curve (zone) of the contact lens collapsed.

[0066] To this end, the mold material of the present invention is manufactured from polyketone rather than PP or PB. Molds manufactured from polyketone possess high dimensional stability and thermal stability.

[0067] Polyketones exhibit short injection cycles and dimensional stability, excellent injection flow, low warpage, and no post-processing required. They also possess excellent resilience and toughness. Furthermore, they exhibit impact properties over a wide temperature range, excellent chemical and gas barrier properties, excellent hydrolysis and friction resistance, and are environmentally friendly.

[0068] In the present invention, the contact lens polymer is composed of a mixture of 40 to 50 wt% of HEMA, 0.05 to 1 wt% of EGDMA, 0.1 to 2 wt% of AIBN, 2 to 10 wt% of MPC, 20 to 60 wt% of DMA, and 5 to 15 wt% of PDMS.

[0069] The above EGDMA acts as a crosslinking agent for synthesizing each component, and if too much is added, polymer synthesis may occur excessively, causing HEMA, an acrylic monomer, and PDMS, a silicone monomer, to become integrated, and if too little is added, the content may be minimal, preventing proper synthesis or bonding between each component.

[0070] The above PDMS is added in amounts of 5 wt% or more, as the oxygen permeability improvement is minimal when the amount added is small. As the amount added increases, the oxygen permeability increases. When added in amounts of 15 wt% or more, there is no significant difference in efficiency.

Claims

1. A step of manufacturing a contact lens polymer by mixing and homogenizing raw materials, then injecting them into a mold and thermally polymerizing them; A pretreatment step of removing the contact lens polymer from the mold and washing away unreacted substances; A step of IPN coating the surface of a contact lens polymer by immersing the contact lens polymer in an IPN solution containing a mangosteen xanthone compound; A post-treatment step to wash away unreacted substances after IPN coating; A method for manufacturing a contact lens using a mangosteen xanthone compound, characterized in that the contact lens is manufactured through a process.

2. In paragraph 1, A method for manufacturing a contact lens using a mangosteen xanthone compound, characterized in that when the above contact lens polymer is IPN coated, the coating is performed by immersing the polymer in an IPN solution at 80 to 90°C for 30 to 180 minutes.

3. In paragraph 1, A method for manufacturing a contact lens using a mangosteen xanthone compound, characterized in that the above IPN solution is composed of 70 to 85 wt% of ultrapure water (DIwater), 3 to 20 wt% of DMA, 0.05 to 1 wt% of AIBN, and 3 to 20 wt% of mangosteen xanthone compound.

4. In paragraph 1, A method for manufacturing a contact lens using a mangosteen xanthone compound, characterized in that the contact lens polymer is composed of a mixture of 40 to 50 wt% of HEMA, 0.05 to 1 wt% of EGDMA, 0.1 to 2 wt% of AIBN, 2 to 10 wt% of MPC, 20 to 60 wt% of DMA, and 5 to 15 wt% of PDMS.

5. In paragraph 1, A method for manufacturing a contact lens using a mangosteen xanthone compound, characterized in that the mold for manufacturing the above contact lens polymer is manufactured from a polyketone material having high dimensional stability and thermal stability.

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