Soft tissue implants and methods for making same

• US 9,750,594 B2
• Filed: 03/29/2013
• Issued: 09/05/2017
• Est. Priority Date: 09/12/2005
• Status: Active Grant

• Current Assignee: Proxy Biomedical Limited
• Original Assignee: Proxy Biomedical Limited
• Inventors: Gingras, Peter, King, Dean
• Primary Examiner(s): Severson, Ryan J
• Assistant Examiner(s): DANG, ANH TIEU
• Application Number:
  US13/853,559
• Publication Number:
  US 20140100590A1
• Time in Patent Office: 1,621 Days
• Field of Search: 623 111, 623 2372, 606213, 606151, 606154
• CPC Class Codes: A61F 2/0063 Implantable repair or support meshes, e.g. hernia meshes
• CPC Class Codes: A61F 2/0077 Special surfaces of prostheses, e.g. for improving ingrowth A61F2/30767 takes precedence

Abstract

The present invention features soft tissue implants comprising major and minor struts and methods for making same. The implants can includes a biocompatible film that is rendered porous due to the inclusion of uniformly or non-uniformly patterned cells, and the film has a thickness of less than about 0.015 inches in the event the starting material is non-porous and less than about 0.035 inches in the event the starting material is a microporous film. Multi-film implants can also be made.

Claims

1. A non-woven soft tissue implant comprising a first porous biocompatible film having a plurality of cells and a second porous biocompatible film having a plurality of cells, the thickness of the non-woven soft tissue implant being less than 0.015 inches, wherein the first porous biocompatible film comprises a plurality of major struts that are made of the first porous biocompatible film and have a width of 0.020 inches to 0.100 inches, and a plurality of minor struts that are made of the first porous biocompatible film and have a width of 0.001 inches to 0.024 inches, wherein the second porous biocompatible film comprises a plurality of major struts that are made of the second porous biocompatible film and have a width of 0.020 inches to 0.100 inches, and a plurality of minor struts that are made of the second porous biocompatible film and have a width of 0.001 inches to 0.024 inches.

2. The non-woven soft tissue implant of claim 1, wherein the first porous biocompatible film and the second porous biocompatible film consist of the same material or materials.

3. The non-woven soft tissue implant of claim 1, wherein the first porous biocompatible film and the second porous biocompatible film consist of different materials.

4. The non-woven soft tissue implant of claim 3, wherein the first porous biocompatible film or the second porous biocompatible film includes a bioresorbable material and a rate at which the first porous biocompatible film is resorbed within a body is different from a rate at which the second porous biocompatible film is resorbed in the body.

5. The non-woven soft tissue implant of claim 1, wherein the first porous biocompatible film and the second porous biocompatible film are of substantially the same size and a surface of the first porous biocompatible film adheres to a surface of the second porous biocompatible film.

6. The non-woven soft tissue implant of claim 1, wherein the first or the second porous biocompatible film comprises an absorbable polymer or copolymer.

7. The non-woven soft tissue implant of claim 1, wherein the first porous biocompatible film or the second porous biocompatible film comprises a cell of the respective plurality of cells having a diameter, measured along the longest axis of the cell, of 10 micrometers to 10,000 micrometers;

of 1,500 micrometers to 5,000 micrometers;

or of 50 micrometers to 100 micrometers.

8. The non-woven soft tissue implant of claim 1, further comprising a film that increases tear resistance.

9. The non-woven soft tissue implant of claim 1, wherein the non-woven soft tissue implant has a tensile strength of at least 10 N/cm.

10. The non-woven soft tissue implant of claim 1, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.014 inches.

11. The non-woven soft tissue implant of claim 10, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.013 inches.

12. The non-woven soft tissue implant of claim 11, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.012 inches.

13. The non-woven soft tissue implant of claim 12, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.011 inches.

14. The non-woven soft tissue implant of claim 13, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.010 inches.

15. The non-woven soft tissue implant of claim 14, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.009 inches.

16. The non-woven soft tissue implant of claim 15, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.008 inches.

17. The non-woven soft tissue implant of claim 16, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.007 inches.

18. The non-woven soft tissue implant of claim 17, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.006 inches.

19. The non-woven soft tissue implant of claim 18, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.005 inches.

20. The non-woven soft tissue implant of claim 19, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.004 inches.

21. The non-woven soft tissue implant of claim 20, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.003 inches.

22. The non-woven soft tissue implant of claim 21, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.002 inches.

23. The non-woven soft tissue implant of claim 22, wherein the thickness of each of the first and/or second porous biocompatible films is or is less than 0.001 inch.