Porous materials, methods of making and uses

• US 9,522,502 B2
• Filed: 10/13/2014
• Issued: 12/20/2016
• Est. Priority Date: 09/28/2010
• Status: Active Grant

• Current Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Original Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Inventors: Liu, Futian, Manesis, Nicholas J., Goraltchouk, Alexei, Stroumpoulis, Dimitrios
• Primary Examiner(s): ZEMEL, IRINA SOPJIA
• Application Number:
  US14/512,839
• Publication Number:
  US 20150028510A1
• Time in Patent Office: 799 Days
• US Class Current: 1/1
• CPC Class Codes: A61K 47/34 Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polyesters, polyamino acids, polysiloxanes, polyphosphazines, copolymers of polyalkylene glycol or poloxamers A61K47/10 takes precedence
• CPC Class Codes: A61L 26/0019 obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: B29C 67/202 comprising elimination of a solid or a liquid ingredient
• CPC Class Codes: B29K 2067/04 Polyesters derived from hydroxycarboxylic acids
• CPC Class Codes: B29K 2083/005 LSR, i.e. liquid silicone rubbers, or derivatives thereof
• CPC Class Codes: B29K 2105/0085 Copolymers
• CPC Class Codes: B29L 2031/753 Medical equipment; Accessories therefor bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008
• CPC Class Codes: C08J 2201/0462 using organic solvents
• CPC Class Codes: C08J 2383/04 Polysiloxanes
• CPC Class Codes: C08J 9/26 by elimination of a solid phase from a macromolecular composition or article, e.g. leaching out
• CPC Class Codes: Y10T 428/249921 Web or sheet containing structurally defined element or component

Abstract

The present specification discloses porous materials, methods of forming such porous materials, materials and devices comprising such porous materials, and methods of making such materials and devices.

Claims

1. A method for forming an elastic, porous structure suitable for implantation in a mammal, the method comprising the steps of:

a) coating porogens with a matrix material to form a matrix material-coated porogen mixture, wherein the matrix material is a poly(lactic-co-glycolic acid) (PLGA);

b) filtering the matrix material-coated porogen mixture through a sieve to remove excess matrix material;

c) pouring the filtered mixture into a mold;

d) treating the filtered mixture to form a scaffold comprising fused porogens and cured matrix material, wherein the scaffold comprises a three-dimensional structure in the form of the mold; and

e) removing the fused porogens from the scaffold, wherein fused porogen removal results in a porous material comprising the cured matrix material defining an array of interconnected pores.

2. The method of claim 1, wherein in the scaffold comprises a three-dimensional structure wherein the diameter of substantially all the connections between each fused porogen in between about 15% to about 80% of the mean porogen diameter.

3. The method of claim 1, wherein the cured matrix material exhibits an elastic elongation of at least 80%.

4. The method of claim 1, wherein the matrix material is a silicone elastomer.

5. The method of claim 1, wherein the porogens are porogens having a diameter of 50 μ

m to about 3000 μ

m.

6. The method of claim 1, wherein the porogens are porogens having a diameter of about 500 μ

m.

7. The method of claim 1, wherein the porogens are porogens having a diameter of about 650 μ

m.

8. A method for forming a tissue engineering scaffold suitable for implantation in a mammal, the method comprising the steps of:

a) coating porogens with a matrix material to form a matrix material-coated porogen mixture, wherein the porogens are porogens having a diameter of 50 μ

m to about 3000 μ

m;

b) filtering the matrix material-coated porogen mixture through a sieve to remove excess matrix material;

c) pouring the filtered mixture into a mold;

d) treating the filtered mixture to form a scaffold comprising fused porogens and cured matrix material, wherein the scaffold comprises a three-dimensional structure in the form of the mold; and

e) removing the fused porogens from the scaffold, wherein fused porogen removal results in a porous material comprising the cured matrix material defining an array of interconnected pores.

9. The method of claim 8, wherein in the scaffold comprises a three-dimensional structure wherein the diameter of substantially all the connections between each fused porogen in between about 15% to about 80% of the mean porogen diameter.

10. The method of claim 8, wherein the cured matrix material exhibits an elastic elongation of at least 80%.

11. The method of claim 8, wherein the matrix material is a silicone elastomer.

12. The method of claim 8, wherein the matrix material is a poly(lactic-co-glycolic acid) (PLGA).

13. The method of claim 8, wherein the porogens are porogens having a diameter of about 500 μ

m.

14. The method of claim 8, wherein the porogens are porogens having a diameter of about 650 μ

m.

15. A method for forming an elastic porous article for biomedical applications, the method comprising the steps of:

a) coating porogens with a matrix material to form a matrix material-coated porogen mixture, wherein the porogens are porogens having a diameter of 50 μ

m to about 3000 μ

m;

b) filtering the matrix material-coated porogen mixture through a sieve to remove excess matrix material;

c) pouring the filtered mixture into a mold;

d) treating the filtered mixture to form a scaffold comprising fused porogens and cured matrix material, wherein the scaffold comprises a three-dimensional structure in the form of the mold; and

e) removing the fused porogens from the scaffold, wherein fused porogen removal results in a porous material comprising the cured matrix material defining an array of interconnected pores.

16. The method of claim 15, wherein the porous article is a membrane for filtration or separation.

17. The method of claim 15, wherein the porous article is a wound dressing.

18. The method of claim 15, wherein the porous article is a drug release matrix.