Reinforced radius mammary prostheses and soft tissue expanders

• US 6,605,116 B2
• Filed: 04/03/2001
• Issued: 08/12/2003
• Est. Priority Date: 04/03/2001
• Status: Expired due to Term

• Current Assignee: Mentor Worldwide LLC (Johnson & Johnson)
• Original Assignee: Mentor Corporation (Johnson & Johnson)
• Inventors: Job, Keith, Weir, Steven, Zhou, Shijung, Falcon, Anita M., Guest, Robert L.
• Primary Examiner(s): Isabella, David J.
• Application Number:
  US09/826,400
• Publication Number:
  US 20020143396A1
• Time in Patent Office: 861 Days
• Field of Search: 623/7, 623/8, 156/215, 156/219, 156/220, 156/229
• US Class Current: 623/8
• CPC Class Codes: A61F 2/12 Mammary prostheses and implants
• CPC Class Codes: Y10T 156/1039 Surface deformation only of sandwich or lamina [e.g., embossed panels]

Abstract

The prosthesis of the invention are configured such that the average thickness of the shell in the region where the posterior and anterior faces meet is greater, e.g., at least twice, the average thickness of the shell in the region of the anterior face. This reinforcement can reduce or eliminate undesirable scalloping effects along the upper perimeter of the prosthesis that can otherwise occur when gravity pulls downward on a filled prosthesis. Moreover, because the reinforcement is preferably confined to a radius/posterior region extending at least part of the way around the perimeter of the prosthesis, it is possible for the shell of the prosthesis in nearly the entire anterior face of the prosthesis to be formed of relatively thin material. This preserves a natural appearance of the prosthesis when it is implanted.

Claims

1. An implantable prosthesis comprising an elastomeric shell having an anterior face, a posterior face, a perimeter region where the anterior face and the posterior face meet, and a smoothly curved transition between the posterior face and the anterior face, wherein the average thickness of the shell in at least a reinforced portion of the perimeter region is greater than the average thickness of the shell in the anterior face, wherein the reinforced portion of the perimeter region extends less than 2 inches, but more than 0.5 inches onto the anterior face of the prosthesis, and wherein there is a smooth transition between the reinforced portion of the perimeter region and the anterior face of the shell on the exterior surface of the shell.

2. The prosthesis of claim 1 wherein the reinforced portion of the perimeter region extends less than 1.5 inches, but more than 0.5 inches onto the anterior face of the prosthesis.

4. The prosthesis of any of claims 1-2 wherein the prosthesis is a mammary prosthesis.

5. The prosthesis of any of claims 1-2 wherein the average thickness of the shell in the reinforced portion of the perimeter region is about 0.02 to 0.08 inches.

6. The prosthesis of claim of any of claims 1-2 wherein the average thickness of the shell in the entire perimeter region is greater than the average thickness of the shell in the anterior face.

7. The prosthesis of any of claims 1-2 wherein the average thickness of the posterior face of the shell is about 0.02 to 0.08 inches.

8. The prosthesis of any of claims 1-2 wherein the average thickness of the anterior face of the shell is less than about 0.04 inches.

9. The prosthesis of claim 8 wherein the average thickness of the anterior face of the shell is less than about 0.03 inches.

10. The prosthesis of any of claims 1-2 wherein the prosthesis is filled with a gel or a liquid.

11. The prosthesis of any of claims 1-2 wherein at least a portion of the posterior face of the shell is textured.

12. The prosthesis of any of claims 1-2 wherein at least a portion of the anterior face of the shell is textured.

13. The prosthesis of claim 12 wherein at least a portion of the posterior face of the shell is textured.

14. The prosthesis of claim 11 wherein the entire posterior face of the shell is textured.

15. The prosthesis of claim 12 wherein the entire anterior face of the shell is textured.

16. The prosthesis of claim 15 wherein the entire posterior face of the shell is textured.

17. The prosthesis of an of claims 1-2 wherein the reinforced portion extends around no more than 90% of the perimeter region.

18. The prosthesis of an of claims 1-2 wherein the reinforced portion extends around no more than 70% of the perimeter region.

19. The prosthesis of any of claims 1-2 wherein the reinforced portion extends around no more than 50% of the perimeter region.

20. The prosthesis of any of claims 1-2 wherein the reinforced portion extends around no more than 30% of the perimeter region.

21. A kit comprising the prosthesis of any of claims 1-2 the shell of the prosthesis further comprising a filling port, the kit further comprising a means for filling the prosthesis with a liquid or a gel.

22. The kit of claim 21 wherein the filling means comprises a syringe and a tube adapted to connect the syringe to the filling port of the shell of the prosthesis.

3. An implantable prosthesis comprising an elastomeric shell having an anterior face, a posterior face, a perimeter region where the anterior face and the posterior face meet, and a smoothly curved transition between the posterior face and the anterior face, wherein the average thickness of the shell in at least a reinforced portion of the perimeter region is greater than the average thickness of the shell in the anterior face, wherein the reinforced portion of the perimeter region extends no more than 0.5 inches onto the anterior face of the prosthesis, and wherein there is a smooth transition between the reinforced portion of the perimeter region and the anterior face of the shell on the exterior surface of the shell.

23. A method for forming a prosthesis, comprising:

(a) providing a mandrel adapted for dip molding a mammary prosthesis, the mandrel having an anterior face, a posterior face and a perimeter region where the anterior face and the posterior face meet;

(b) masking both the anterior face and the posterior face of the mandrel while leaving at least a portion of the perimeter region free of masking, wherein the perimeter region free of masking extends less than 2 inches but more than 0.5 inches onto the anterior face of the prosthesis;

(c) dipping the masked mandrel into a silicone dispersion at least one time;

(d) removing the mandrel from the silicone dispersion;

(e) removing the masking from the mandrel; and

(f) dipping the unmasked mandrel into a silicone dispersion at least one time.

25. The method of claim 23 or 24 wherein the perimeter region free of masking extends less than 1.5 inches, but more than 0.5 inches onto the anterior face of the mandrel.

28. The method of any of claims 23-27 wherein the masked mandrel is dipped into a silicone dispersion at least two times.

29. The method of any of claims 23-27 wherein the unmasked mandrel is dipped into a silicone dispersion at least two times.

24. A method for forming a prosthesis, comprising:

(a) providing a mandrel adapted for dip molding a mammary prosthesis, the mandrel having an anterior face, a posterior face and a perimeter region where the anterior face and the posterior face meet;

(b) masking the anterior face of the mandrel while leaving at least a portion of the perimeter region and the posterior face free of masking, wherein the perimeter region free of masking extends less than 2 inches but more than 0.5 inches onto the anterior face of the prosthesis;

(c) dipping the masked mandrel into a silicone dispersion at least one time;

(d) removing the mandrel from the silicone dispersion;

(e) removing the masking from the mandrel; and

(f) dipping the unmasked mandrel into a silicone dispersion at least one time.

26. A method for forming a prosthesis, comprising:

(a) providing a mandrel adapted for dip molding a mammary prosthesis, the mandrel having an anterior face, a posterior face and a perimeter region where the anterior face and the posterior face meet;

(b) masking both the anterior face and the posterior face of the mandrel while leaving at least a portion of the perimeter region free of masking, wherein the perimeter region free of masking extends no more than 0.5 inches onto the anterior face of the prosthesis;

(c) dipping the masked mandrel into a silicone dispersion at least one time;

(d) removing the mandrel from the silicone dispersion;

(e) removing the masking from the mandrel; and

(f) dipping the unmasked mandrel into a silicone dispersion at least one time.

27. A method for forming a prosthesis, comprising:

(a) providing a mandrel adapted for dip molding a mammary prosthesis, the mandrel having an anterior face, a posterior face and a perimeter region where the anterior face and the posterior face meet;

(b) masking the anterior face of the mandrel while leaving at least a portion of the perimeter region and the posterior face free of masking, wherein the perimeter region free of masking extends no more than 0.5 inches onto the anterior face of the prosthesis;

(c) dipping the masked mandrel into a silicone dispersion at least one time;

(d) removing the mandrel from the silicone dispersion;

(e) removing the masking from the mandrel; and

(f) dipping the unmasked mandrel into a silicone dispersion at least one time.

30. A method for forming a prosthesis shell, comprising:

(a) dipping an appropriately sized and shaped mandrel into a silicone dispersion such that the posterior face and perimeter of the mandrel, but not the entire anterior face of the mandrel is submerged in the dispersion, wherein the portion of the anterior face that is submerged in the dispersion extends less than 2 inches, but more than 0.5 inches from the perimeter of the mandrel onto the anterior face;

(b) repeating step (a) until a desired partial thickness is achieved;

(c) dipping the entire mandrel into the dispersion;

(d) repeating step (c) until a desired final thickness is achieved.

31. The method of claim 30 wherein the portion of the anterior face that is submerged in the dispersion extends less than 0.5 inches, but more than 0.5 inches from the perimeter of the mandrel onto the anterior face.

32. A method for forming a prosthesis shell, comprising:

(a) dipping an appropriately sized and shaped mandrel into a silicone dispersion such that the posterior face and perimeter of the mandrel, but not the entire anterior face of the mandrel is submerged in the dispersion, wherein the portion of the anterior face that is submerged in the dispersion extends no more than 1.5 inches from the perimeter of the mandrel onto the anterior face;

(b) repeating step (a) until a desired partial thickness is achieved;

(c) dipping the entire mandrel into the dispersion;

(d) repeating step (c) until a desired final thickness is achieved.

33. A method for forming a reinforced mammary prosthesis, comprising:

(a) forming an elastomeric mammary prosthesis shell, the shell having an inner surface, an outer surface, anterior face, a posterior face, a perimeter region where the anterior face and the posterior face meet and a smoothly curved transition between the posterior face and the anterior face of the shell; and

(b) adhering a sheet a of elastomeric material to the inner surface of the shell at the perimeter region, wherein the elastomeric material adhered to the perimeter region extends less than 2 inches, but more than 0.5 inches onto the anterior face of the prosthesis.

34. The method of claim 33 wherein the elastomeric material to the perimeter region extends less than 1.5 inches, but more than 0.5 inches onto the anterior face of the prosthesis.

35. A method for forming a reinforced mammary prosthesis, comprising:

(a) forming an elastomeric mammary prosthesis shell, the shell having an inner surface, an outer surface, anterior face, a posterior face, a perimeter region where the anterior face and the posterior face meet and a smoothly curved transition between the posterior face and the anterior face of the shell; and

(b) adhering a sheet a of elastomeric material to the inner surface of the shell at the perimeter region, wherein the elastomeric material adhered to the perimeter region extends no more than 0.5 inches onto the anterior face of the prosthesis.