Porogen compositions, methods of making and uses

• US 8,877,822 B2
• Filed: 09/27/2011
• Issued: 11/04/2014
• 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:
  US13/246,568
• Publication Number:
  US 20120077891A1
• Time in Patent Office: 1,134 Days
• Field of Search: 521/61, 521/82, 521/146, 521/148, 521/154
• US Class Current: 521/61
• 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 of making a porous material, the method comprising the steps of:

a) coating porogens with a matrix material to form a matrix material-coated porogen mixture, the porogens comprising a shell material and a core material, wherein the core material is a sugar and the shell material is polyethylene glycol, and further wherein the shell material has a melting temperature that is lower than a melting temperature of the core material;

b) treating the matrix material-coated porogen mixture to form a porogen scaffold comprising fused porogens and stabilized matrix material; and

c) removing the porogen scaffold from the stabilized matrix material, wherein porogen scaffold removal results in a porous material, the porous material comprising a matrix defining an array of interconnected pores.

2. The method of claim 1 wherein the porous material is a porous silicone elastomer.

3. The method of claim 1 wherein the step of treating comprises heat treatment.

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

5. A method of making a porous material, the method comprising the steps of:

a) coating porogens with a matrix material to form a matrix material-coated porogen mixture, 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;

b) treating the matrix material-coated porogen mixture to form a porogen scaffold comprising fused porogens and stabilized matrix material; and

c) removing the porogen scaffold from the stabilized matrix material, wherein porogen scaffold removal results in a porous material, the porous material comprising a matrix defining an array of interconnected pores;

wherein the porous material is a porous silicone elastomer.

6. The method of claim 5 wherein the step of treating comprises heat treatment.