FOAM-LIKE MATERIALS AND METHODS FOR PRODUCING SAME

• US 20140154491A1
• Filed: 02/06/2014
• Published: 06/05/2014
• Est. Priority Date: 04/27/2010
• Status: Abandoned Application

• Current Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Original Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Inventors: Goraltchouk, Alexei, Thompson, Jordan, Abiad, Miriam M., Van Epps, Dennis, Manesis, Nicholas J., Ma, Kevin
• Application Number:
  US14/174,111
• Publication Number:
  US 20140154491A1
• Time in Patent Office: Days
• US Class Current: 428/220
• 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 porous material made by the steps of:

providing a polyurethane foam base material having a porous surface;

contacting the base material with a first fluid material;

drawing the first fluid material into intimate contact with the base material to form a coat of the first fluid material on the base material;

curing the coat on the base material; and

removing the base material from the cured coat, resulting in a porous material comprising the cured first fluid material.

2. The porous material of claim 1 wherein the step of drawing the first fluid material into intimate contact with the base material includes using a vacuum.

3. The porous material of claim 2 further comprising using positive air pressure to blow away excess fluid material from the base material before the step of curing.

4. The porous material of claim 1 wherein the first fluid material is a silicone elastomer dispersion.

5. The porous material of claim 1, wherein the base material is removed by dissolution.

6. The porous material of claim 1 wherein the step of removing the base material comprises removing all of the base material from the cured first fluid material.

7. The porous material of claim 1 wherein the step of removing the base material comprises contacting the base material with a solution, mixture, suspension, emulsion, dispersion or combination thereof capable of dissolving the base material.

8. The porous material of claim 1 wherein the step of removing 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.

9. The porous material of claim 1 wherein the coat has a thickness of about 10 μ

m to about 500 μ

m.

10. The porous material of claim 1 wherein the coat has a thickness of about 50 μ

m to about 100 μ

m.

11. The porous material of claim 1 further comprising repeating the contacting step to achieve a desired thickness of the coat.

18. The porous material of claim 1 further comprising repeating the contacting step to achieve a desired thickness of the coating.

12. A porous material made by the steps of:

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

contacting the base material with a liquid silicone dispersion to form a coating on the base material;

removing a portion of the liquid silicone dispersion 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 liquid silicone dispersion remaining on the base material after the step of removing a portion, to form a cured silicone elastomer coating on the base material; and

removing the base material from the silicone elastomer coating, thereby leaving a porous material comprising silicone.

13. The porous material of claim 12 further comprising using positive air pressure or a vacuum to remove excess fluid material from the base material before the step of curing.

14. The porous material of claim 12 wherein the step of removing the base material comprises contacting the base material with a solution capable of dissolving the base material.

15. The porous material of claim 12 wherein the step of removing 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.

16. The porous material of claim 12 wherein the coating has a thickness of about 10 μ

m to about 500 μ

m.

17. The porous material of claim 12 wherein the coating has a thickness of about 50 μ

m to about 100 μ

m.