Porous materials, methods of making and uses

• US 9,044,897 B2
• Filed: 09/28/2011
• Issued: 06/02/2015
• Est. Priority Date: 09/28/2010
• Status: Active Grant

• Current Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Original Assignee: Allergan, Inc. (Canada) (Abbvie Incorporated)
• Inventors: Manesis, Nicholas J., Liu, Futian
• Primary Examiner(s): YI, STELLA KIM
• Application Number:
  US13/247,535
• Publication Number:
  US 20120077010A1
• Time in Patent Office: 1,343 Days
• Field of Search: 264/413, 264/414, 264/48, 264/628, 264/629, 264/630, 264634-637
• US Class Current: 1/1
• CPC Class Codes: B29C 67/20 for porous or cellular articles, e.g. of foam plastics, coarse-pored chemical aspects of working up macro-molecular substances to porous or cellular articles C08J9/00
• CPC Class Codes: B32B 2262/02 Synthetic macromolecular fibres
• CPC Class Codes: B32B 2305/026 Porous
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12

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 elastomeric porous material, the method comprising the steps of:

a) applying a silicone elastomer matrix material to a contoured mold having the shape of a breast implant;

b) applying a fibrous covering to the silicone elastomer matrix material on the contoured mold wherein the fibrous covering comprises polymer fibers having an average thickness between about 100 μ

m and 1000 μ

m;

c) treating the silicone elastomer matrix material having the fibrous covering to cure the silicone elastomer matrix material on the mold; and

d) removing the fibrous covering from the cured silicone elastomer matrix material, wherein fibrous covering removal results in a porous silicone elastomer material defining an array of interconnected tunnels and channels, the porous silicone elastomer material having a thickness of at least 300 μ

m, and the porous silicone elastomer material is in the form of a breast implant shell.

2. The method of claim 1, wherein the polymer fibers comprise poly(L-lactic acid-co-trimethylcarbonate), polycaprolactone, poly(methylmethacrylate), poly(L-lactic acid), poly(lactic-co-glycolic acid), poly(ethylene-vinylacetate), poly(hydroxybutyrate-co-valerate), polydioxanone, polyorthoester, polyanhydride, poly(glycolic acid), poly(D,L-lactic acid), poly(glycolic acid-co-trimethylene carbonate), polyphosphoester, polyphosphoester urethane, poly(amino acids), cyanoacrylates, poly(trimethylene carbonate), poly(iminocarbonate), copoly(ether-esters), polyalkylene oxalates, polyphosphazenes, fibrin, fibrinogen, cellulose, starch, collagen hyaluronic acid, or combinations thereof.

3. The method of claim 1, wherein the fibrous covering comprises a fiber assemblage including a plurality of eyes having a mean area of about 50 μ

m² to about 2000 μ

m².

4. The method of claim 3, wherein the fiber assemblage comprises a plurality of layers.

5. The method of claim 4, wherein the fiber assemblage is a mesh or a felt.

6. The method of claim 1, wherein steps (a) and (c) are repeated at least once before step (d) is performed.

7. The method of claim 1, wherein steps (a), (b), and (c) are repeated at least once before step (d) is performed.

8. The method of claim 1, wherein step (b) is repeated at least once before step (d) is performed.

9. The method of claim 1, wherein the fibrous covering comprises poly(L-lactic acid).

10. The method of claim 1, wherein step (b) is done before step (a).