Porogen compositions, methods of making and uses

• US 9,593,224 B2
• Filed: 10/01/2014
• Issued: 03/14/2017
• 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., Yu, Xiaojie, Chan, Athene Wan Chie
• Primary Examiner(s): ZEMEL, IRINA SOPJIA
• Application Number:
  US14/504,329
• Publication Number:
  US 20150057381A1
• Time in Patent Office: 895 Days
• US Class Current: 1/1
• 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 27/56 Porous materials, e.g. foams or sponges
• 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: A61L 31/146 Porous materials, e.g. foams or sponges
• CPC Class Codes: B01D 2239/1208 Porosity apparatus incorporating such gas filtering material B01D2275/30 - B01D2275/307
• CPC Class Codes: B01D 2239/1216 Pore size
• CPC Class Codes: B01D 39/1692 Other shaped material, e.g. perforated or porous sheets
• CPC Class Codes: B05D 1/38 with intermediate treatment intermediate treatment per se B05D3/00
• CPC Class Codes: B05D 3/007 After-treatment
• CPC Class Codes: B05D 5/00 Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
• CPC Class Codes: C08J 2201/04 characterised by the elimination of a liquid or solid component, e.g. precipitation, leaching out, evaporation
• CPC Class Codes: C08J 2201/042 Elimination of an organic solid phase
• CPC Class Codes: C08J 2201/0422 containing oxygen atoms, e.g. saccharose
• CPC Class Codes: C08J 2201/0462 using organic solvents
• CPC Class Codes: C08J 2201/0464 using water or inorganic fluids
• CPC Class Codes: C08J 2201/05 Elimination by evaporation or heat degradation of a liquid phase
• CPC Class Codes: C08J 2205/05 Open cells, i.e. more than 50% of the pores are open
• CPC Class Codes: C08J 2207/10 Medical applications, e.g. biocompatible scaffolds
• CPC Class Codes: C08J 2207/12 Sanitary use, e.g. diapers, napkins or bandages
• CPC Class Codes: C08J 2325/10 with conjugated dienes
• CPC Class Codes: C08J 2353/02 : of vinyl aromatic monomers and conjugated dienes
• CPC Class Codes: C08J 2375/04 : Polyurethanes
• 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: C09D 167/04 : Polyesters derived from hydroxycarboxylic acids, e.g. lactones C09D167/06 takes precedence
• CPC Class Codes: C09D 171/02 : Polyalkylene oxides

Abstract

Provided are porogen compositions and methods of using such porogen compositions in the manufacture of porous materials, for example, porous silicone elastomers. The porogens generally include comprising a core material and shell material different from the core material. The porogens can be used to form a scaffold for making a resulting porous elastomer when the scaffold is removed.

Claims

1. A method for making an article including a porous elastomeric surface, the method comprising the steps of:

a) coating a mandrel with an elastomer;

b) curing the elastomer to form a cured elastomer base layer on the mandrel;

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

d) coating the additional elastomer with porogens to form an elastomer coated porogen mixture on the cured elastomer base layer, the porogens comprising 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 cured elastomer, wherein 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 is between about 15% to about 80% of a mean porogen diameter; and

f) removing the fused porogens from the cured elastomer, wherein fused porogen removal results in a 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 core material is a sugar and the shell material is polyethylene glycol.