Porogen compositions, method of making and uses

• US 8,685,296 B2
• Filed: 05/10/2011
• Issued: 04/01/2014
• Est. Priority Date: 05/11/2010
• Status: Active Grant

• Current Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Original Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Inventors: Liu, Futian, Manesis, Nicholas J., Yu, Xiaojie, Chan, Athene W.
• Primary Examiner(s): DANIELS, MATTHEW J
• Application Number:
  US13/104,811
• Publication Number:
  US 20110278755A1
• Time in Patent Office: 1,057 Days
• Field of Search: 264/49, 264/233, 264/344
• US Class Current: 264/49
• CPC Class Codes: A61F 2/12 Mammary prostheses and implants
• CPC Class Codes: A61L 2430/04 for mammary reconstruction
• CPC Class Codes: A61L 27/16 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: A61L 27/18 obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: A61L 27/50 Materials characterised by their function or physical properties , e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
• CPC Class Codes: A61L 27/56 Porous materials, e.g. foams or sponges
• CPC Class Codes: A61L 27/58 Materials at least partially resorbable by the body
• CPC Class Codes: A61L 31/10 Macromolecular materials
• CPC Class Codes: C08L 23/22 Copolymers of isobutene; Butyl rubber ; Homo- or copolymers of other iso-olefins
• CPC Class Codes: C08L 53/02 of vinyl-aromatic monomers and conjugated dienes
• CPC Class Codes: C08L 83/04 Polysiloxanes
• CPC Class Codes: Y10T 428/2989 Microcapsule with solid core [includes liposome]

Abstract

The present specification discloses porogen compositions comprising a core material and shell material, methods of making such porogen compositions, methods of forming such porous materials using such porogen compositions, biocompatible implantable devices comprising such porous materials, and methods of making such biocompatible implantable devices.

Claims

1. A method for making a biocompatible implantable device comprising the step of:

a) coating a mandrel with an elastomer base;

b) curing the elastomer base to form a base layer;

c) coating the cured base layer with an elastomer base;

d) coating the elastomer base with porogens to form an elastomer coated porogen mixture, the porogens comprise a shell material and a core material, wherein the shell material has a melting temperature that is lower than a melting temperature of the core material;

e) treating the elastomer coated porogen mixture to form a porogen scaffold comprising fused porogens and cure the elastomer base, wherein the porogen scaffold comprises a three-dimensional structure where substantially all the fused porogens are each connected to at least four other fused porogens, and wherein the diameter of substantially all the connections between each fused porogen in between about 15% to about 80% of the mean porogen diameter; and

f) removing the porogen scaffold, wherein porogen scaffold removal results in a porous material, the porous material comprising a non-degradable, biocompatible, elastomer matrix defining an array of interconnected pores.

2. The method of claim 1, wherein steps (b) and (c) are repeated at least once.

3. The method of claim 1, wherein steps (b) and (c) are repeated at least repeated twice.

4. The method of claim 1 wherein the shell material is selected from a group consisting of a salt, a ceramic, a sugar, a polysaccharide, a wax, a metal, a surfactant, a water soluble solid, a polymer, composites thereof, and combinations thereof.

5. The method of claim 4 wherein the core material is selected from a group consisting of a salt, a ceramic, a sugar, a polysaccharide, a wax, a metal, a water soluble solid, a polymer, composites thereof, and combinations thereof.

6. The method of claim 4 wherein the shell material is a polymer.

7. The method of claim 6 wherein the core material is a sugar.