FOAM-LIKE MATERIALS AND METHODS FOR PRODUCING SAME

• US 20110313073A1
• Filed: 04/25/2011
• Published: 12/22/2011
• Est. Priority Date: 04/27/2010
• Status: Active Grant

• Current Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Original Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Inventors: Goraltchouk, Alexei, Thompson, Jordan M., Abiad, Miriam M., Ma, Kevin A., Van Epps, Dennis E., Manesis, Nicholas J.
• Granted Patent: US 8,679,570 B2
• Time in Patent Office: Days
• US Class Current: 521/154
• CPC Class Codes: C08J 2201/046 Elimination of a polymeric phase
• CPC Class Codes: C08J 9/26 by elimination of a solid phase from a macromolecular composition or article, e.g. leaching out
• CPC Class Codes: C08J 9/365 Coating

Abstract

Described herein are foam-like materials having substantially the same physical structure of polyurethane foams but with properties that can be tailored for a particular application. Methods of forming these foam-like materials are also described.

Claims

1. A method of making a foam-like material comprising:

providing a base material having a porous surface;

contacting the base material with a first fluid material;

removing a portion of the first fluid material from the base material;

curing the first fluid material remaining on the base material after the step of removing a portion; and

removing at least a portion of the base material from the cured first fluid material thereby leaving a foam-like material comprising the cured first fluid material having a porous surface substantially identically conforming to the porous surface of the base material.

2. The method of claim 1 wherein the step of removing a portion of the first fluid material includes using a vacuum to draw the first fluid material into intimate contact with the porous surface of the base material.

3. The method of claim 2 wherein the step of removing a portion of the first fluid material further includes using positive air pressure to blow away excess fluid material.

4. The method of claim 1 wherein the step of removing a portion of the first fluid material includes using positive air pressure to blow away excess fluid material.

5. A foam-like material made by the method of claim 1.

6. The method of claim 1 wherein the first fluid material is a silicone elastomer dispersion.

7. The method of claim 1 wherein the first fluid material is a Styrene Isoprene Styrene dispersion.

8. The method of claim 1 wherein the first fluid material is a fluoroelastomer dispersion.

9. The method of claim 1, wherein the base material is removed by dissolution.

10. The method of claim 1 wherein the base material is an open cell foam.

11. The method of claim 1 wherein the base material is a polyurethane foam.

12. The method of claim 1 wherein the base material is a polyurethane foam and the first fluid material is a fluoroelastomer dispersion.

13. The method of claim 1 wherein the base material is a polyurethane foam and the first fluid material is a styrene isoprene styrene dispersion.

14. The method of claim 1 wherein the step of removing at least a portion of the base material comprises removing substantially all of the base material from the cured first fluid material.

15. The method of claim 1 wherein the step of removing at least a portion of the base material comprises contacting the base material with a solution, mixture suspension, emulsion, dispersion or combination thereof capable of dissolving the base material.

16. The method of claim 1 wherein the step of removing at least a portion of the base material comprises degradation or dissolution of the base material with a base, a solvent, an enzyme, an acid, heat, oxidation, ultraviolet light, gamma irradiation, visible light, infrared light or a combination thereof.

20. The method of claim 1 wherein the first fluid material is a fluoroelastomer dispersion.

17. A method of making a foam-like material comprising:

providing a open cell polyurethane foam base material having a porous surface;

contacting the base material with a first fluid material comprising an elastomeric dispersion to form a conformal coating on the base material;

removing a portion of the first fluid material from the base material by using a vacuum to draw the first fluid material into intimate contact with the porous surface of the base material and using positive air pressure to blow away excess fluid material;

curing the first fluid material remaining on the base material after the step of removing a portion; and

removing by dissolving at least a portion of the base material from the cured first fluid material thereby leaving a foam-like material comprising the cured first fluid material having a porous surface substantially identically conforming to the porous surface of the base material.

18. The method of claim 17 wherein the first fluid material is a silicone elastomer dispersion.

19. The method of claim 17 wherein the first fluid material is a Styrene Isoprene Styrene dispersion.

21. A foam-like material made by the steps of:

providing a open cell foam base material having a porous surface;

contacting the base material with a first fluid material comprising an elastomeric dispersion to form a conformal coating on the base material;

removing a portion of the first fluid material from the base material by using a vacuum to draw the first fluid material into intimate contact with the porous surface of the base material and using positive air pressure to blow away excess fluid material;

curing the first fluid material remaining on the base material after the step of removing a portion; and

removing by dissolving at least a portion of the base material from the cured first fluid material thereby leaving a foam-like material comprising the cured first fluid material having a porous surface substantially identically conforming to the porous surface of the base material.