Making a soft tissue prosthesis for repairing a defect of an abdominal wall or a pelvic cavity wall

• US 8,460,695 B2
• Filed: 10/23/2012
• Issued: 06/11/2013
• Est. Priority Date: 04/20/2004
• Status: Active Grant

• Current Assignee: Genzyme Corporation (Sanofi )
• Original Assignee: Genzyme Corporation (Sanofi )
• Inventors: Greenawalt, Keith E.
• Primary Examiner(s): Azpuru, Carlos
• Assistant Examiner(s): HAGOPIAN, CASEY SHEA
• Application Number:
  US13/658,385
• Publication Number:
  US 20130045327A1
• Time in Patent Office: 231 Days
• Field of Search: None
• US Class Current: 424/423
• CPC Class Codes: A61F 2/0063 Implantable repair or support meshes, e.g. hernia meshes
• CPC Class Codes: A61F 2250/003 differing in adsorbability or resorbability, i.e. in adsorption or resorption time
• CPC Class Codes: A61F 2250/0031 made from both resorbable and non-resorbable prosthetic parts, e.g. adjacent parts
• CPC Class Codes: A61L 27/507 for artificial blood vessels apparatus for applying cells on a blood vessel prosthesis A61F2/062
• CPC Class Codes: A61L 27/58 Materials at least partially resorbable by the body
• CPC Class Codes: A61L 31/04 Macromolecular materials
• CPC Class Codes: A61L 31/148 Materials at least partially resorbable by the body
• CPC Class Codes: C08L 23/10 Homopolymers or copolymers of propene
• CPC Class Codes: C08L 23/12 Polypropene
• CPC Class Codes: C08L 5/04 Alginic acid; Derivatives thereof
• CPC Class Codes: C08L 67/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds C08L67/06 takes precedence
• CPC Class Codes: C08L 67/04 Polyesters derived from hydroxycarboxylic acids, e.g. lactones C08L67/06 takes precedence

Abstract

Surgical prostheses and methods of using and making surgical prostheses are disclosed.

Claims

1. A method of making a surgical prosthesis, the method comprising the steps of:

providing a fabric comprising a first layer formed substantially of non-biodegradable yarn and a second layer formed of biodegradable yarn;

providing a liquid formulation comprising macromers and an initiator;

placing the fabric within the liquid formulation such that the second layer is in fluid contact with the liquid formulation; and

exposing the liquid formulation to a light source.

2. The method of claim 1, wherein the initiator is a photoinitiator.

3. The method of claim 2, wherein the photoinitiator comprises Eosin Y.

4. The method of claim 1, wherein the liquid formulation further comprises biopolymers, an accelerant and a buffer.

5. The method of claim 4, wherein the biopolymers comprise at least one polyanionic polysaccharide modified by reaction with carbodiimide.

6. The method of claim 4, wherein the buffer comprises triethanolamine.

7. The method of claim 4, wherein the buffer comprises potassium phosphate.

8. The method of claim 4, wherein the accelerant comprises N-vinylcaprolactam.

9. The method of claim 1, wherein the liquid formulation comprises 1 weight percent of carbodiimide-modified hyaluronic acid and carboxymethylcellulose, 2.5 weight percent poly(ethylene glycol)-trimethlyene carbonate/lactate multi-block polymers endcapped with acrylate esters, 40 ppm of Eosin Y, 4000 ppm N-vinylcaprolactam, 0.54 weight percent triethanolamine, 0.8 weight percent of potassium phosphate.

10. The method of claim 1, wherein the light source is an LED array having an intensity of about 1 to about 100 mW/cm2.

11. A method of making a surgical prosthesis, the method comprising the steps of:

providing a fabric comprising a first layer formed substantially of non-biodegradable yarn and a second layer formed of biodegradable yarn;

providing a liquid formulation comprising a first polymer system, a second polymer system, and a photoinitiator;

placing the fabric over the liquid formulation such that the second layer is in fluid contact with the liquid formulation; and

exposing the liquid formulation to a light source to activate the photoinitiator so as to cause polymerization of at least one of the polymer systems in the liquid formulation.

12. The method of claim 11, wherein the polymerization of at least one of the polymer systems results in the formation of a barrier layer partially embedded within the second layer of the fabric.

13. The method of claim 12, wherein the first polymer system comprises carbodiimide-modified hyaluronic acid and carbodiimide-modified carboxymethylcellulose and the second polymer system comprises poly(ethylene glycol)-trimethylene carbonate/lactate multi-block polymers endcapped with acrylate esters.

14. The method of claim 13, wherein the photoinitiator comprises Eosin Y.

15. The method of claim 14, wherein the liquid formulation further comprises an accelerant and at least one buffer.

16. The method of claim 15, wherein the liquid formulation further comprises a first buffer and a second buffer.

17. The method of claim 16, wherein the accelerant comprises N-vinylcaprolactam, the first buffer comprises triethanolamine, and the second buffer comprises potassium phosphate.

18. The method of claim 11, wherein the light source is an LED array having an intensity of about 1 to about 100 mW/cm2.

19. The method of claim 12, further comprising drying the fabric and the barrier layer in a connection oven.