Absorbable Medical Devices Based on Novel Films and Foams Made From Semi-Crystalline, Segmented Copolymers of Lactide and Epsilon-Caprolactone Exhibiting Long Term Absorption Characteristics
AssigneeEthicon, Inc.
InventorsSasa Andjelic, Dennis D. Jamiolkowski, Jackie Donners, Mark Timmer
Life of this patent
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Abstract
Absorbable medical devices based on novel foams and films made from semi-crystalline, segmented copolymers of lactide and epsilon-caprolactone exhibiting long term absorption characteristics are disclosed. Also disclosed are methods of producing said foams and films, and useful polymer solutions.
Claims25
An absorbable foam, comprising a semicrystalline absorbable segmented copolymer, said copolymer comprising repeating units of polymerized lactide and polymerized epsilon-caprolactone, wherein the mole ratio of polymerized lactide to polymerized epsilon-caprolactone is between about 60:40 to about 75:25, said copolymer having a first heat Tg, as determined by differential scanning calorimetry at a scan rate of 10° C. per minute, equal to or less than 0° C., and a crystallinity level of about 20 percent to about 50 percent, as measured by wide angle X-ray diffraction.
A method of making an absorbable foam by a melt process, comprising the steps of:
- A. providing an absorbable polymer comprising a semicrystalline absorbable segmented copolymer, said copolymer comprising repeating units of polymerized lactide and polymerized epsilon-caprolactone, wherein the mole ratio of polymerized lactide to polymerized epsilon-caprolactone is between about 60:40 to about 75:25, said copolymer having a first heat Tg, as determined by differential scanning calorimetry at a scan rate of 10° C. per minute, equal to or less than 0° C., and a crystallinity level of about 20 to about 50 percent, as measured by wide angle X-ray diffraction, said copolymer having a melt temperature;
- B. heating the copolymer above the melt temperature to form a melt;
- C. introducing a suitable blowing agent (chemical or physical) into the melt;
- and
- D. enabling the gas produced from the blowing agent to expand within the melt to form an absorbable foam.
A method of making an absorbable foam by a melt process, comprising the steps of:
- A. providing an absorbable polymer comprising a semicrystalline absorbable segmented copolymer, said copolymer comprising repeating units of polymerized lactide and polymerized epsilon-caprolactone, wherein the mole ratio of polymerized lactide to polymerized epsilon-caprolactone is between about 60:40 to about 75:25, said copolymer having a first heat Tg, as determined by differential scanning calorimetry at a scan rate of 10° C. per minute, equal to or less than 0° C., and a crystallinity level of about 20 to about 50 percent, as measured by wide angle X-ray diffraction, said copolymer having a melt temperature;
- B. transferring the said absorbable polymer to the hopper of a melt extruder outfitted with a profile die, with a barrel outfitted with a gas injection port, and die heated to a temperature within the range of about 10° C. above the melt temperature of said absorbable polymer to about 270° C. to form a melt;
- C. extruding said absorbable polymer through said profile die, while injecting into the melt through the gas injection port a gas selected from the group of carbon dioxide, nitrogen, helium, and argon, resulting in a foam;
- and,
- D. collecting said foam at a rate to result in a foam thickness between about 0.1 mils and 50 mils.
A method of making an absorbable foam by a melt process, comprising the steps of:
- A. providing an absorbable polymer comprising a semicrystalline absorbable segmented copolymer, said copolymer comprising repeating units of polymerized lactide and polymerized epsilon-caprolactone, wherein the mole ratio of polymerized lactide to polymerized epsilon-caprolactone is between about 60:40 to about 75:25, said copolymer having a first heat Tg, as determined by differential scanning calorimetry at a scan rate of 10° C. per minute, equal to or less than 0° C., and a crystallinity level of about 20 to about 50 percent, as measured by wide angle X-ray diffraction, said copolymer having a melt temperature;
- B. transferring the said absorbable polymer in combination with a solid blowing agent to the hopper of a melt extruder outfitted with a profile die, and die heated to a temperature within the range of about 10° C. above the melt temperature of said absorbable polymer to about 270° C.;
- C. extruding said absorbable polymer through said profile die, resulting in a foam;
- and,
- D. collecting said foam at a rate to result in a foam thickness between about 0.1 mils and 50 mils.
A method of making an absorbable foam by a lyophilization process, comprising the steps of:
- A. providing an absorbable polymer comprising a semicrystalline absorbable segmented copolymer, said copolymer comprising repeating units of polymerized lactide and polymerized epsilon-caprolactone, wherein the mole ratio of polymerized lactide to polymerized epsilon-caprolactone is between about 60:40 to about 75:25, said copolymer having a first heat Tg, as determined by differential scanning calorimetry at a scan rate of 10° C. per minute, equal to or less than 0° C., and a crystallinity level of about 20 to about 50 percent, as measured by wide angle X-ray diffraction;
- B. dissolving a sufficient quantity of the copolymer in a suitable solvent to form a lyophilizing solution;
- C. pouring at least a part of the solution into a suitable mold;
- and,
- D. subjecting the solution in the mold to a lyophilizing process to form an absorbable foam.
A lyophilizing solution, comprising:
- A. a solvent selected from the group consisting of 1,4-dioxane, trioxane, a mixture of at least 90 weight percent 1,4-dioxane and no more than 10 weight percent water, and a mixture of at least 90 weight percent 1,4-dioxane and no more than 10 weight percent of an organic alcohol having a molecular weight of less than 1500 Daltons;
- and,
- B. about 3 wt. % to about 30 wt. % of a polymer comprising a semicrystalline absorbable segmented copolymer, the copolymer comprising repeating units of polymerized lactide and polymerized epsilon-caprolactone, wherein the mole ratio of polymerized lactide to polymerized epsilon-caprolactone is between about 60:40 to about 75:25, said copolymer having a first heat Tg, as determined by differential scanning calorimetry at a scan rate of 10° C. per minute, equal to or less than 0° C., and a crystallinity level of about 20 to about 50 percent, as measured by wide angle X-ray diffraction.
An absorbable film comprising a semicrystalline absorbable segmented copolymer, the copolymer comprising repeating units of polymerized lactide and polymerized epsilon-caprolactone, wherein the mole ratio of polymerized lactide to polymerized epsilon-caprolactone is between about 60:40 to about 75:25, said copolymer having a first heat Tg, as determined by differential scanning calorimetry at a scan rate of 10° C. per minute, equal to or less than 0° C., and a crystallinity level of about 20 to about 50 percent, as measured by wide angle X-ray diffraction.
A method of making an absorbable film by melt processing, comprising the steps of:
- A. providing an absorbable polymer comprising a semicrystalline absorbable segmented copolymer, the copolymer comprising repeating units of polymerized lactide and polymerized epsilon-caprolactone, wherein the mole ratio of polymerized lactide to polymerized epsilon-caprolactone is between about 60:40 to about 75:25, said copolymer having a first heat Tg, as determined by differential scanning calorimetry at a scan rate of 10° C. per minute, equal to or less than 0° C., and a crystallinity level of about 20 to about 50 percent, as measured by wide angle X-ray diffraction, said copolymer having a melt temperature;
- B. transferring the said absorbable polymer to the hopper of a melt extruder outfitted with a slit die, with a barrel and die temperature within the range of about 10° C. above the melt temperature of the said absorbable polymer to about 270° C.;
- C. extruding said absorbable polymer through said slit die, resulting in a film;
- and,
- D. drawing said film to a draw ratio between about 0.8× to about 10× to form a film having a thickness between about 0.1 mils and 50 mils.
A method of making an absorbable film by a solution process, comprising the steps of:
- A. providing an absorbable polymer comprising a semicrystalline absorbable segmented copolymer, said copolymer comprising repeating units of polymerized lactide and polymerized epsilon-caprolactone, wherein the mole ratio of polymerized lactide to polymerized epsilon-caprolactone is between about 60:40 to about 75:25, said copolymer having a first heat Tg, as determined by differential scanning calorimetry at a scan rate of 10° C. per minute, equal to or less than 0° C., and a crystallinity level of about 20 to about 50 percent, as measured by wide angle X-ray diffraction;
- B. dissolving a sufficient quantity of the copolymer in a suitable solvent to form a polymer solution;
- C. pouring at least a part of the solution into a suitable mold or dispensing the polymer solution onto a conveying surface;
- and,
- D. allowing the solvent to be removed from the polymer solution to form an absorbable film.
Dependencies are inferred from the claim text.