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Methods of making doubly porous device

  • US 5,589,176 A
  • Filed: 06/07/1995
  • Issued: 12/31/1996
  • Est. Priority Date: 10/18/1991
  • Status: Expired due to Term
First Claim
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1. A method of forming a device having a first porous portion having continuously interconnected pores and a second porous portion having continuously interconnected pores, said method comprising the steps of:

  • (a) obtaining an open-cell porous mold form corresponding to the first porous portion, said open-cell porous mold form comprising particles formed into a mass of continuously interconnected particles and shaped and solidified to thereby define continuously interconnected pores and connecting interstices within said first porous portion;

    (b) selectively forming a stable coating layer upon the surface of the particles of said mold form to thereby define continuously interconnected pores and connecting interstices within the second porous portion, said stable coating layer being formed by the steps of;

    i) selectively filling said pores and interstices of said open-cell porous mold form with a selected coating material such that the open-cell porous mold form mass is maintained;

    ii) selectively removing a substantial portion of said coating material such that a continuous coating of a selected thickness remains upon the particles of said open-cell porous mold form; and

    iii) solidifying said coating material; and

    (c) selectively removing the open-cell porous mold form such that the stable coating layer defines a membrane separating the first porous portion and the second porous portion of said device.

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