Spun nanofiber, medical devices, and methods

• US 20070144124A1
• Filed: 12/23/2005
• Published: 06/28/2007
• Est. Priority Date: 12/23/2005
• Status: Active Grant

• Current Assignee: Boston Scientific Scimed (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Scimed (Boston Scientific Corporation)
• Inventors: Schewe, Scott, Warner, Robert, Atanasoska, Liliana, Zoromski, Michele
• Granted Patent: US 8,455,088 B2
• Time in Patent Office: Days
• US Class Current: 55/487
• CPC Class Codes: A61L 2400/12 Nanosized materials, e.g. nanofibres, nanoparticles, nanowires, nanotubes; Nanostructured surfaces
• CPC Class Codes: A61L 27/306 Other specific inorganic materials not covered by A61L27/303 - A61L27/32
• CPC Class Codes: A61L 27/446 with other specific inorganic fillers other than those covered by A61L27/443 or A61L27/46
• CPC Class Codes: A61L 29/126 having a macromolecular matrix
• CPC Class Codes: A61L 31/088 Other specific inorganic materials not covered by A61L31/084 or A61L31/086
• CPC Class Codes: A61L 31/128 containing other specific inorganic fillers not covered by A61L31/126 or A61L31/127
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C03B 37/011 starting from a liquid phase reaction process, e.g. through a gel phase
• CPC Class Codes: D01D 5/003 the material being a polymer solution or dispersion D01D5/0053 takes precedence
• CPC Class Codes: D01F 9/00 Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments
• CPC Class Codes: D04H 1/42 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
• CPC Class Codes: D04H 3/02 characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
• CPC Class Codes: D04H 3/16 with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/24994 Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/249941 Fiber is on the surface of a polymeric matrix having no embedded portion

Abstract

The present disclosure relates to compounds from which nanofibers can be produced, the resulting nanofibers produced from the compounds, and nanofiber reinforced polymers prepared using the nanofibers and a polymer. The compounds used in forming the nanofibers include chemical linkage moieties that are capable of forming non-covalent bonds with portions of the polymer so as to form the nanofiber reinforced polymers. The nanofiber reinforced polymers are useful as biomaterials in medical devices.

Claims

1. A method of preparing a nanofiber, comprising:

providing at least one compound of the formula (Formula I);

[(R₂O)₃—

Si—

R₃]_z—

Y—

[(R₁)_m—

O_x]_q—

Y′

—

[R₃—

Si—

(OR₂)₃]_Z

where x and z are each independently 0 or 1;

m is 1 to 18;

q is 1 to 200;

R₁, R₂ and R₃ are each independently an organic group; and

Y and Y′

are selected together from the group consisting of;

—

NH—

(C═

O)—

O—

for Y and —

(C═

O)—

NH—

for Y′

where z=1;


—

NH—

(C═

O)—

for Y and —

(C═

O)—

NH—

for Y′

where x=0 and z=1;

—

O—

(C═

O)—

for Y and —

(C═

O)—

for Y′

where z=1;


—

NR₄)—

(C═

O)—

(NH)—

for Y and Y′

, where z=1, and R₄ is an organic group or H;


and
—

N—

[CH₂—

(CHOH)—

CH₂—

O—

R₃—

Si—

(OR₂)₃]₂ for Y and Y′

, where z=0;

forming a cross-linked network from at least one compound of Formula I using a sol-gel process; and

spinning the nanofiber from a solution of the cross-linked network from the at least one compound of Formula I.

2. The method of claim 1, where spinning the nanofiber includes electrospinning the nanofiber from the solution of the cross-linked network from the at least one compound of Formula I.

3. The method of claim 1, where spinning the nanofiber includes dry-spinning the nanofiber from the solution of the cross-linked network from the at least one compound of Formula I.

4. The method of claim 1, where spinning the nanofiber includes collecting the nanofiber on a polymer having a functional group that can non-covalently bond with the group Y to form a biomaterial.

5. The method of claim 1, where spinning the nanofiber includes collecting the nanofiber on a surface of a mold used to shape a medical device.

6. The method of claim 5, including injection molding a polymer at least partially around the nanofiber collected on the surface of the mold, where the polymer includes a chemical moiety capable of forming a non-covalently bond with the group Y.

7. The method of claim 1, where each R₁ and R₃ is independently a (C1-C18)alkylene group, and R₂ is a (C1-C18)alkyl group.

8. A nanofiber formed from a compound of the formula (Formula I):

[(R₂O)₃—

Si—

R₃]_z—

Y—

[(R₁)_m—

O_x]_q—

Y′

—

[R₃—

Si—

(OR₂)₃]_z

where x and z are each independently 0 or 1;

m is 1 to 18;

q is 1 to 200;

R₁, R₂ and R₃ are each independently an organic group; and

Y and Y′

are selected together from the group consisting of;

—

NH—

(C═

O)—

O—

for Y and —

(C═

O)—

NH—

for Y′

where z=1;


—

NH—

(C═

O)—

for Y and —

(C═

O)—

NH—

for Y′

where x=0 and z=1;

—

O—

(C═

O)—

for Y and —

(C═

O)—

for Y′

where z=1;


—

(NR₄)—

(C═

O)—

(NH)—

for Y and Y′

, where z=1, and R₄ is an organic group or H;


and
—

N—

[CH₂—

(CHOH)—

CH₂—

O—

R₃—

Si—

(OR₂)₃]₂ for Y and Y′

, where z=0;

produced by a spinning process.

9. The nanofiber of claim 8, where the spinning process used to produce the nanofiber is a dry-spinning process.

10. The nanofiber of claim 8, where the spinning process used to produce the nanofiber is an electrospinning process.

11. The nanofiber of claim 8, where the nanofiber is used as a reinforcement component with a polymer to form a biomaterial.

12. The nanofiber of claim 11, where the nanofiber coats the polymer to form the biomaterial.

13. The nanofiber of claim 11, where the nanofiber is embedded in the polymer to form the biomaterial.

14. The nanofiber of claim 11, where the nanofiber includes chemical moieties that can non-covalently bond with portions of the polymer.

15. The nanofiber of claim 8, where the compound of Formula I can form a cross-linked network using a sol-gel process.

16. A medical device prepared from the nanofiber of claim 8.

17. The nanofiber of claim 8, where each R₁ and R₃ is independently a (C1-C18)alkylene group, and R₂ is a (C1-C18)alkyl group.

18. A nanofiber reinforced polymer, comprising:

a polymer; and

nanofibers of a cross-linked network of a metal-oxide based polymer formed through a sol-gel process, where the metal-oxide based polymer includes chemical moieties capable of forming a non-covalently bond with portions of the polymer.

19. The reinforced polymer of claim 18, where the nanofibers coat a surface of at least a portion of the polymer.

20. The reinforced polymer of claim 19, where the nanofibers are in a random pattern on the surface of at least a portion of the polymer.

21. The reinforced polymer of claim 18, where the nanofibers are imbedded in at least a portion of the polymer.

22. The reinforced polymer of claim 21, where the nanofibers are in a random pattern imbedded in at least a portion of the polymer.

23. The reinforced polymer of claim 18, where the metal-oxide based polymer of the cross-linked network is formed using at least one compound of the formula (Formula I):

[(R₂O)₃—

Si—

R₃]_z—

Y—

[(R₁)_m—

O_x]_q—

Y′

—

[R₃—

Si—

(OR₂)₃]_z

in the sol-gel process, where x and z are each independently 0 or 1;

m is 1 to 18;

q is 1 to 200;

R₁, R₂ and R₃ are each independently an organic group; and

Y and Y′

are selected together from the group consisting of;

—

NH—

(C═

O)—

O—

for Y and —

(C═

O)—

NH—

for Y′

where z=1;


—

NH—

(C═

O)—

for Y and —

(C═

O)—

NH—

for Y′

where x=0 and z=1;

—

O—

(C═

O)—

for Y and —

(C═

O)—

for Y′

where z=1;


—

(NR₄)—

(C═

O)—

(NH)—

for Y and Y′

, where z=1, and R₄ is an organic group or H;


and
—

N—

[CH₂—

(CHOH)—

CH₂—

O—

R₃—

Si—

(OR₂)₃]₂ for Y and Y′

, where z=0;

where Y is a chemical moiety that can non-covalently bond with portions of the polymer.

24. The reinforced polymer of claim 23, where each R₁ and R₃ is independently a (C1-C18)alkylene group, and R₂ is a (C1-C18)alkyl group.

25. The reinforced polymer of claim 18, where the portions of the polymer that can chemically bond with chemical moieties of the metal-oxide based polymer are selected from the group of a urethane, an ester, an amide, an imide, a urea and a combination thereof.

26. The reinforced polymer of claim 18, where the polymer is selected from the group polyamide, polyurethane, polyurea, polyurethane-urea, and polyester.

27. A biomaterial comprising the reinforced polymer of claim 18.

28. A medical device comprising the reinforced polymer of claim 18.