Method of making a medical textile from polyhydroxyalkanoate fibers

• US 9,333,066 B2
• Filed: 05/13/2014
• Issued: 05/10/2016
• Est. Priority Date: 05/08/2003
• Status: Active Grant

• Current Assignee: Tepha Incorporated (Becton, Dickinson & Co)
• Original Assignee: Tepha Incorporated (Becton, Dickinson & Co)
• Inventors: Martin, David P., Rizk, Said, Ahuja, Ajay, Williams, Simon F.
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US14/276,708
• Publication Number:
  US 20140246802A1
• Time in Patent Office: 728 Days
• Field of Search: 264/103, 264/210.7, 264/210.8, 264/211.14, 264/211.15, 528/361
• US Class Current: 1/1
• CPC Class Codes: A61F 2/0063 Implantable repair or support meshes, e.g. hernia meshes
• CPC Class Codes: A61F 2002/0068 having a special mesh pattern
• CPC Class Codes: A61L 27/18 obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: A61L 27/48 with macromolecular fillers
• CPC Class Codes: A61L 31/06 obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds A61L31/041 takes precedence
• CPC Class Codes: B29C 48/022 characterised by the choice of material
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 71/0072 for changing orientation
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2031/753 Medical equipment; Accessories therefor bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008
• CPC Class Codes: C08L 67/04 Polyesters derived from hydroxycarboxylic acids, e.g. lactones C08L67/06 takes precedence
• CPC Class Codes: D01D 5/088 Cooling filaments, threads or the like, leaving the spinnerettes
• CPC Class Codes: D01D 5/098 with simultaneous stretching
• CPC Class Codes: D01D 5/16 using rollers, or like mechanical devices, e.g. snubbing pins
• CPC Class Codes: D01F 6/62 from polyesters
• CPC Class Codes: D01F 6/625 derived from hydroxy-carboxylic acids, e.g. lactones
• CPC Class Codes: D01F 6/84 from copolyesters
• CPC Class Codes: D02G 3/02 Yarns or threads characterised by the material or by the materials from which they are made
• CPC Class Codes: Y10T 428/1362 Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
• CPC Class Codes: Y10T 428/1369 Fiber or fibers wound around each other or into a self-sustaining shape [e.g., yarn, braid, fibers shaped around a core, etc.]
• CPC Class Codes: Y10T 428/249922 : Embodying intertwined or helical component[s]
• CPC Class Codes: Y10T 442/10 : Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
• CPC Class Codes: Y10T 442/183 : Synthetic polymeric fiber
• CPC Class Codes: Y10T 442/184 : Nonwoven scrim
• CPC Class Codes: Y10T 442/2525 : Coating or impregnation functions biologically [e.g., insect repellent, antiseptic, insecticide, bactericide, etc.]

Abstract

Absorbable polyester fibers, braids, and surgical meshes with prolonged strength retention have been developed. These devices are preferably derived from biocompatible copolymers or homopolymers of 4-hydroxybutyrate. These devices provide a wider range of in vivo strength retention properties than are currently available, and could offer additional benefits such as anti-adhesion properties, reduced risks of infection or other post-operative problems resulting from absorption and eventual elimination of the device, and competitive cost. The devices may also be particularly suitable for use in pediatric populations where their absorption should not hinder growth, and provide in all patient populations wound healing with long-term mechanical stability. The devices may additionally be combined with autologous, allogenic and/or xenogenic tissues to provide implants with improved mechanical, biological and handling properties.

Claims

1. A method of making a medical textile from a fiber comprising poly-4-hydroxybutyrate polymer (P4HB), wherein the fiber has a tensile strength greater than 126 MPa, comprising melt extruding the P4HB polymer, allowing the extruded fiber time to crystallize and cool at or to a temperature that is greater than the glass transition temperature of the polymer, and stretching the fiber at a temperature above the polymer'"'"'s glass transition temperature.

2. The method of claim 1 wherein the fiber has been heat set.

3. The method of claim 1 wherein the medical textile is a mesh or braid.

4. The method of claim 3 wherein the mesh is knitted, woven or braided.

5. The method of claim 4 wherein the mesh is a monofilament mesh.

6. The method of claim 5 wherein the mesh is a warp knit.

7. The method of claim 6 wherein the fiber has an elongation to break of over 20%.

8. The method of claim 3 wherein the braid is formed from a multifilament yarn of poly-4-hydroxybutyrate polymer.

9. The method of claim 8 wherein the braid comprises multifilament yarn and monofilament of poly-4-hydroxybutyrate polymer.

10. The method of claim 1 wherein the medical textile has a breaking strength of at least 10 psi.

11. The method of claim 1 wherein the diameter of the fiber is between 82 μ

m and 217 μ

m.

12. The method of claim 1 wherein the medical textile is selected from the group consisting of a tube, general surgical mesh, suture, hernia mesh, pericardial patch, anti-adhesion patch, cardiovascular patch, guided tissue regeneration patch, sling, braid, ligament and tendon repair device, meniscus repair device, cartilage repair device, nerve guide, stent, vascular graft, dural patch, organ salvage device, intracardiac defect closure device, mastopexy/breast reconstruction device, tracheal reconstruction device and bladder repair device.

13. The method of claim 1 wherein the polymer is a copolymer of 4-hydroxybutyrate and one or more co-monomers.

14. The method of claim 13 wherein the co-monomer is glycolate or 3-hydroxybutyrate.

15. The method of claim 1 wherein the medical textile is combined with harvested autologous, allogeneic and/or xenogeneic tissue.

16. The method of claim 1 wherein the medical textile is used for hernia repair, mastopexy/breast reconstruction, rotator cuff repair, suturing, wound healing, vascular grafting/fistulae, tissue flaps, pericardial patching in intracardiac repair, tissue heart valve implants, bowel interposition, and dura patching.