POROGEN COMPOSITIONS, METHODS OF MAKING AND USES
First Claim
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1. A method of making a porous material, the method comprising the steps of:
- a) coating porogens with a matrix material to form a matrix material-coated porogen mixture, the porogens comprise a shell material and a core material, wherein the shell material has a melting temperature that is lower than a melting temperature of the core material;
b) treating the matrix material-coated porogen mixture to form a porogen scaffold comprising fused porogens and stabilized matrix material; and
c) removing the porogen scaffold from the stabilized matrix material, wherein porogen scaffold removal results in a porous material, the porous material comprising a matrix defining an array of interconnected pores.
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Abstract
Provided are porogen compositions and methods of using such porogen compositions in the manufacture of porous materials, for example, porous silicone elastomers. The porogens generally include comprising a core material and shell material different from the core material. The porogens can be used to form a scaffold for making a resulting porous elastomer when the scaffold is removed.
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Citations
23 Claims
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1. A method of making a porous material, the method comprising the steps of:
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a) coating porogens with a matrix material to form a matrix material-coated porogen mixture, the porogens comprise a shell material and a core material, wherein the shell material has a melting temperature that is lower than a melting temperature of the core material; b) treating the matrix material-coated porogen mixture to form a porogen scaffold comprising fused porogens and stabilized matrix material; and c) removing the porogen scaffold from the stabilized matrix material, wherein porogen scaffold removal results in a porous material, the porous material comprising a matrix defining an array of interconnected pores. - View Dependent Claims (2, 3, 4)
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5. A porogen composition useful to form a scaffold for making a porous material, the composition comprising:
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a) a shell material; and b) a core material; wherein under a given physical or physicochemical treatment the shell material is fusible and the core material is non-fusible. - View Dependent Claims (6, 7, 8, 9, 10, 11)
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12. A method of making a porogen composition useful to form a scaffold for making a porous material, the method comprising the steps of:
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a) forming a particle out of a core material; and b) coating the particle with a shell material; wherein the porogen composition comprises a shell material and a core material, wherein the shell material has a melting temperature that is lower than a melting temperature of the core material. - View Dependent Claims (13, 14, 15)
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16. A method for making an article including a porous elastomeric surface, the method comprising the steps of:
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a) coating a mandrel with an elastomer base; b) curing the elastomer base to form a base layer; c) coating the cured base layer with an elastomer base; d) coating the elastomer base with porogens to form an elastomer coated porogen mixture, the porogens comprise a shell material and a core material, wherein the shell material has a melting temperature that is lower than a melting temperature of the core material; e) treating the elastomer coated porogen mixture to form a porogen scaffold comprising fused porogens and cure the elastomer base, wherein the porogen scaffold comprises a three-dimensional structure where substantially all the fused porogens are each connected to at least four other fused porogens, and wherein the diameter of substantially all the connections between each fused porogen in between about 15% to about 80% of the mean porogen diameter; and f) removing the porogen scaffold, wherein porogen scaffold removal results in a porous material, the porous material comprising a non-degradable, biocompatible, elastomer matrix defining an array of interconnected pores. - View Dependent Claims (17, 18, 19)
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20. An article of manufacture comprising;
an elastomeric porous material made by the method of; a) coating porogens with a matrix material to form a matrix material-coated porogen mixture, the porogens comprise a shell material and a core material, wherein the shell material has a melting temperature that is lower than a melting temperature of the core material; b) treating the matrix material-coated porogen mixture to form a porogen scaffold comprising fused porogens and stabilized matrix material; and c) removing the porogen scaffold from the stabilized matrix material, wherein porogen scaffold removal results in a porous material, the porous material comprising a matrix defining an array of interconnected pores. - View Dependent Claims (21, 22, 23)
Specification