Methods for creating foam-like texture

• US 8,679,279 B2
• Filed: 11/15/2011
• Issued: 03/25/2014
• Est. Priority Date: 11/16/2010
• Status: Active Grant

• Current Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Original Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Inventors: Thompson, Jordan M., Goraltchouk, Alexei, Ma, Kevin A.
• Primary Examiner(s): Tucker, Philip
• Assistant Examiner(s): Wu, Vicki
• Application Number:
  US13/297,120
• Publication Number:
  US 20130013062A1
• Time in Patent Office: 861 Days
• Field of Search: 156/242
• US Class Current: 156/242
• CPC Class Codes: A61F 2/0077 Special surfaces of prostheses, e.g. for improving ingrowth A61F2/30767 takes precedence
• CPC Class Codes: A61F 2/12 Mammary prostheses and implants
• CPC Class Codes: A61F 2240/001 Designing or manufacturing processes
• CPC Class Codes: A61L 2400/08 Methods for forming porous structures using a negative form which is filled and then removed by pyrolysis or dissolution
• CPC Class Codes: A61L 2400/18 Modification of implant surfaces in order to improve biocompatibility, cell growth, fixation of biomolecules, e.g. plasma treatment
• CPC Class Codes: A61L 2430/04 for mammary reconstruction
• CPC Class Codes: A61L 27/34 Macromolecular materials
• CPC Class Codes: A61L 27/56 Porous materials, e.g. foams or sponges
• CPC Class Codes: B29C 41/14 Dipping a core B29C41/10 takes precedence
• CPC Class Codes: B29C 43/02 of articles of definite length, i.e. discrete articles B29C35/0227 takes precedence
• CPC Class Codes: B29C 59/005 characterised by the choice of material
• CPC Class Codes: B29C 59/02 by mechanical means, e.g. pressing B29C59/007 takes precedence; embossing expanded porous articles B29C44/5627
• CPC Class Codes: B29C 65/483 Reactive adhesives, e.g. chemically curing adhesives
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29K 2083/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
• CPC Class Codes: B29L 2031/7532 Artificial members, protheses
• CPC Class Codes: C08L 83/04 Polysiloxanes

Abstract

Methods for creating a foam-like texture on an implantable material are provided. More particularly, methods for creating foam-like texture on implantable silicone materials are provided.

Claims

1. A method of making a textured breast implant, the method comprising:

applying a texturing material onto a mandrel having the shape of a breast implant;

placing a polyurethane foam sheet onto the texturing material;

causing integration between the texturing material and the polyurethane foam sheet by pressing the polyurethane foam sheet into the texturing material;

generating a composite of cured texturing material and polyurethane foam by curing the texturing material after the step of causing integration; and

after the step of generating the composite by curing, removing the polyurethane foam from the cured texturing material by application of a solvent of polyurethane to the composite, to thereby obtain a material having the shape of a breast implant and a surface texture characterized by interconnected pores.

2. The method of claim 1, further comprising using clamps to stabilize the polyurethane foam sheet as it is placed onto and integrated with the texturing material.

3. The method of claim 1, wherein the texturing material is a silicone material.

6. The method of claim 1 wherein the solvent is hydrochloric acid.

7. The method of claim 1 wherein the solvent is hexane.

8. The method of claim 1 wherein the solvent is dimethyl sulfoxide (DMSO).

4. A method of producing a textured surface on an implantable breast prosthesis, the method comprising:

applying a base coat to a breast implant mandrel;

applying to the base coat, a texturing material comprising an uncured silicone dispersion;

placing a polyurethane foam sheet onto the texturing material;

applying pressure to integrate the polyurethane foam and the texturing material;

curing the texturing material with the polyurethane foam integrated thereto;

after the step of curing, removing the polyurethane foam from the cured texturing material by application of a solvent capable of dissolving polyurethane, to thereby obtain a material having the shape of a breast implant and a surface texture characterized by interconnected pores.

5. The method of claim 4, wherein the thickness of the polyurethane foam sheet is between about 0.1 mm to about 250 mm and the thickness of the texturing material is between about 0.1 mm to about 50 mm.

9. The method of claim 4 wherein the solvent is hydrochloric acid.

10. The method of claim 4 wherein the solvent is hexane.

11. The method of claim 4 wherein the solvent is dimethyl sulfoxide (DMSO).