METHODS FOR CREATING FOAM-LIKE TEXTURE

• US 20140156002A1
• Filed: 02/06/2014
• Published: 06/05/2014
• Est. Priority Date: 11/16/2010
• Status: Active Grant

• Current Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Original Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Inventors: Thompson, Jordan, Goraltchouk, Alexei, Ma, Kevin
• Granted Patent: US 9,155,613 B2
• Time in Patent Office: Days
• US Class Current: 623/8
• CPC Class Codes: A61F 2/0077 Special surfaces of prostheses, e.g. for improving ingrowth A61F2/30767 takes precedence
• CPC Class Codes: A61F 2/12 Mammary prostheses and implants
• CPC Class Codes: A61F 2240/001 Designing or manufacturing processes
• 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 2400/18 Modification of implant surfaces in order to improve biocompatibility, cell growth, fixation of biomolecules, e.g. plasma treatment
• CPC Class Codes: A61L 2430/04 for mammary reconstruction
• CPC Class Codes: A61L 27/34 Macromolecular materials
• CPC Class Codes: A61L 27/56 Porous materials, e.g. foams or sponges
• CPC Class Codes: B29C 41/14 Dipping a core B29C41/10 takes precedence
• CPC Class Codes: B29C 43/02 of articles of definite length, i.e. discrete articles B29C35/0227 takes precedence
• CPC Class Codes: B29C 59/005 characterised by the choice of material
• CPC Class Codes: B29C 59/02 by mechanical means, e.g. pressing B29C59/007 takes precedence; embossing expanded porous articles B29C44/5627
• CPC Class Codes: B29C 65/483 Reactive adhesives, e.g. chemically curing adhesives
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29K 2083/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
• CPC Class Codes: B29L 2031/7532 Artificial members, protheses
• CPC Class Codes: C08L 83/04 Polysiloxanes

Abstract

Methods for creating a foam-like texture on an implantable material are provided. More particularly, methods for creating foam-like texture on implantable silicone materials are provided.

Claims

1. A textured breast prosthesis made by the steps of:

applying a base coat to a breast implant mandrel;

applying to the base coat, an uncured silicone dispersion;

placing a polyurethane foam sheet onto the silicone dispersion;

applying pressure to integrate the polyurethane foam and the silicone dispersion;

curing the silicone dispersion with the polyurethane foam integrated thereto;

after the step of curing, removing the polyurethane foam from the cured silicone by application of a solvent capable of dissolving polyurethane, to thereby obtain a textured breast implant shell.

2. The prosthesis of claim 1 wherein the thickness of the polyurethane foam sheet is between about 0.1 mm to about 250 mm.

3. The prosthesis of claim 1 wherein the thickness of the silicone dispersion is between about 0.1 mm to about 50 mm.

4. The prosthesis of claim 1 wherein the solvent is hydrochloric acid.

5. The prosthesis of claim 1 wherein the solvent is hexane.

6. The prosthesis of claim 1 wherein the solvent is dimethyl sulfoxide (DMSO).

7. The prosthesis of claim 1 wherein the solvent is hydrochloric acid.

8. A textured breast prosthesis made by the steps of:

applying a texturing material onto a mandrel having the shape of a breast implant;

placing a polyurethane foam sheet onto the texturing material;

causing integration between the texturing material and the polyurethane foam sheet by pressing the polyurethane foam sheet into the texturing material;

generating a composite of cured texturing material and polyurethane foam by curing the texturing material after the step of causing integration; and

after the step of generating the composite by curing, removing the polyurethane foam from the cured texturing material by application of a solvent of polyurethane to the composite, to thereby obtain a textured breast implant shell.

9. The prosthesis of claim 8, further comprising using clamps to stabilize the polyurethane foam sheet as it is placed onto and integrated with the texturing material.

10. The prosthesis of claim 8, wherein the texturing material is a silicone material.

11. The prosthesis of claim 8 wherein the thickness of the polyurethane foam sheet is between about 0.1 mm to about 250 mm.

12. The prosthesis of claim 8 wherein the thickness of the silicone dispersion is between about 0.1 mm to about 50 mm.

13. The prosthesis of claim 8 wherein the solvent is hydrochloric acid.

14. The prosthesis of claim 8 wherein the solvent is hexane.

15. The prosthesis of claim 8 wherein the solvent is dimethyl sulfoxide (DMSO).

16. The prosthesis of claim 8 wherein the solvent is hydrochloric acid.