Bi-phasic compressed porous reinforcement materials suitable for implant
First Claim
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1. A biphasic porous device suitable for implantation in a living being, said porous implantable device:
- (a) being in the form of a flexible/bendable sheet that comprises;
(b) at least two porous sheets layered together, the layered sheets defining;
(i) a plurality of low density porous zones, and(ii) at least one high density porous zone, wherein said plurality of low density porous zones are arranged within the at least one high density porous zone; and
(c) wherein said at least two porous sheets are bonded to each other at said at least one high density porous zone.
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Abstract
A high strength porous biphasic polymeric reinforcement material manufactured by a compression and/or sintering process is disclosed. The material results in a network of interconnected collapsed pores, which forces thin overlapping walls and passages to be created. The network provides permeable access for fluid migration throughout the material. The strength and/or permeability are advantageous for medical devices and implants.
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Citations
24 Claims
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1. A biphasic porous device suitable for implantation in a living being, said porous implantable device:
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(a) being in the form of a flexible/bendable sheet that comprises; (b) at least two porous sheets layered together, the layered sheets defining; (i) a plurality of low density porous zones, and (ii) at least one high density porous zone, wherein said plurality of low density porous zones are arranged within the at least one high density porous zone; and (c) wherein said at least two porous sheets are bonded to each other at said at least one high density porous zone. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 19, 20, 21, 22, 23, 24)
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11. A method of producing a high density, high strength porous matrix sheet containing low-density zones comprising:
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a) creating at least two high porosity polymeric matrix sheets by methods known in the art; b) inducing glass-transition within said porous polymeric matrix sheets; c) placing the at least two sheets atop one another in a layered or laminated fashion; d) applying a compressive force within one or more dimensions using a plate containing shaped cavities, wherein the shaped cavities allow for less compression than the areas of the plate surrounding the cavities to achieve a new size or shape; e) holding the porous polymer matrix sheets above glass transition at the new size and shape for a period of time allowing the molecular chains within the matrix sheets that are under compression to rotate or move to a lower energy state; and f) cooling the porous polymer to below the glass-transition wherein the polymer matrix sheets maintain the new size or shape.
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12. A porous device suitable for implantation in a living being, said porous device comprising:
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(a) at least one non-porous sheet and at least one porous sheet layered together, the porous sheet layer comprising; (i) a plurality of low density porous zones, and (ii) at least one high density porous zone, wherein said plurality of low density porous zones are arranged within the at least one high density porous zone; (b) wherein said at least two sheets are bonded to each other at said at least one high density porous zone; (c) the non-porous sheet and the porous sheet defining a plurality of containment spaces therebetween; (d) the non-porous sheet defining a surface of said porous device; (e) the at least one high density porous zone defining a plane; and (f) the containment spaces being located above said plane.
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13. A method of producing a high density, high strength porous matrix sheet containing low-density zones comprising:
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a) creating a high porosity polymeric matrix sheet by methods known in the art; b) inducing glass-transition within said porous polymeric matrix sheet; c) placing the porous polymeric sheet atop a non-porous sheet in a layered or laminated fashion; d) applying a compressive force within one or more dimensions using a plate containing shaped cavities, wherein the shaped cavities allow for less compression than the areas of the plate surrounding the cavities to achieve a new size or shape; e) holding the porous polymer matrix sheet above glass transition at the new size and shape for a period of time allowing the molecular chains within the matrix sheets that are under compression to rotate or move to a lower energy state; and f) cooling the porous polymer to below the glass-transition wherein the polymer matrix sheets maintain the new size or shape and fuses with the non-porous sheet.
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14. A porous device suitable for implantation in a living being, said porous device:
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(a) being in the form of a flexible/bendable sheet that comprises; (b) at least one porous sheet and at least one non-porous sheet layered together, the layered sheets defining; (i) a plurality of low density porous zones, and (ii) at least one non-porous zone, wherein said plurality of low density porous zones are arranged within the at least one non-porous zone; (c) wherein said at least two sheets are bonded to each other at said at least one non-porous zone. - View Dependent Claims (15, 16, 17, 18)
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Specification