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US 2022/0033611 A1Published application
Biocompatible porous materials and methods of manufacture and use
AssigneePoragen LLC
InventorsNicholas J. MANESIS, Dylan B. HOLLRIGEL
Life of this patent
Estimating the term…
Abstract
Methods and materials used for production of constructs having a porous open or semi-open celled structure. Constructs may include a porous matrix as a base and a biocompatible conformal coating thereon.
Claims68
A method of making a biocompatible open or semi-open celled construct for medical applications, the method comprising:
- submerging an open or semi-open celled polyurethane foam matrix into a silicone dispersion to expose the polyurethane foam template to the silicone dispersion, the polyurethane foam template comprising a plurality of template struts that define a plurality of template pores,
- allowing the silicone to pass into the plurality of template pores;
- removing at least some of the silicone dispersion from the plurality of template pores;
- curing the silicone to form a conformal silicone coating on the plurality of template struts,
- at a time subsequent to the curing step, increasing the compliance of the silicone coated template struts compared to a compliance of the silicone coated template struts with the increasing step;
- at a time subsequent to the curing step, forming a hydrophilic layer on the conformal silicone coating to impart wettability, wherein forming a hydrophilic layer on the conformal silicone coating creates a construct including a plurality of construct struts that define a plurality of construct pores,
- the plurality of construct struts having a thickness from 30 microns to 90 microns,
- the conformal silicone coating having a thickness from 1 micron to 20 microns, and
- wherein the construct is 80-98% open pore.
6 more elements
A method of making a biocompatible open or semi-open celled construct for medical applications, the method comprising:
- exposing an open or semi-open celled polyurethane foam matrix to a silicone dispersion, the polyurethane foam template comprising a plurality of template struts that define a plurality of template pores,
- allowing silicone dispersion to pass into the plurality of template pores;
- removing at least some of the silicone dispersion from the plurality of template pores;
- curing the silicone to form a plurality of construct struts that comprise a conformal silicone coating on the plurality of template struts, the plurality of construct struts defining a plurality of construct pores;
- and
- increasing the compliance of the plurality of construct struts relative to a compliance subsequent the curing step.
3 more elements
A biocompatible open or semi-open celled material for medical applications, comprising:
- an open or semi-open celled construct, comprising
- a plurality of struts having a thickness from 30 microns to 95 microns, the plurality of struts including
- a polyurethane template, and
- a conformal silicone layer on the polyurethane template, the conformal silicone layer having a thickness from 1 micron to 20 microns, and
- a hydrophilic coating on the conformal silicone layer adapted to impart wettability to the construct, the hydrophilic coating having a thickness less than 5 microns,
- the plurality of struts defining a plurality of pores, the construct being 80-98% open pore, and
- the plurality of pores having a diameter from 200 to 900 microns.
4 more elements
A biocompatible open or semi-open celled material for medical applications, comprising:
- an open or semi-open celled construct, including,
- a plurality of struts having a thickness from 30 microns to 95 microns, the plurality of struts including
- a polyurethane matrix;
- and
- a conformal silicone coating on the polyurethane template, the conformal silicone coating having a thickness from 1 micron to 20 microns, and
- the plurality of struts defining a plurality of pores, the construct being 80-98% open pore, and
- the plurality of pores having a diameter from 200 to 900 microns.
4 more elements
A biocompatible open or semi-open celled material for medical applications, comprising:
- an open or semi-open celled construct, including,
- a plurality of struts the plurality of struts having a thickness from 30 microns to 90 microns, the plurality of struts including
- a polyurethane matrix;
- and
- a conformal silicone coating on the polyurethane template, the conformal silicone coating having a thickness from 1 micron to 20 microns, and
- the plurality of struts defining a plurality of pores, the construct being 80-98% open pore, wherein the construct, in an image of a top or a bottom of the construct, has an open area %, defined as open space between the plurality of struts, from 20-35%.
3 more elements
A biocompatible open or semi-open celled material for medical applications, comprising:
- an open or semi-open celled construct, including,
- a plurality of struts having a thickness from 30 microns to 90 microns, the plurality of struts including
- a polyurethane matrix;
- and
- a conformal silicone coating on the polyurethane template, the conformal silicone coating having a thickness from 1 micron to 20 microns, and
- the plurality of struts defining a plurality of pores, the construct being 80-98% open pore,
- wherein the construct, in an image taken of a cross-section that is orthogonal to a top and a bottom of the construct, has an open area %, defined as open space between the plurality of struts, from 20-35%.
4 more elements
A biocompatible open or semi-open celled material for medical applications, comprising:
- an open or semi-open celled construct, including,
- a plurality of struts having a thickness from 30 microns to 90 microns, the plurality of struts including
- a polyurethane matrix;
- and
- a conformal silicone coating on the polyurethane matrix, the conformal silicone coating having a thickness from 1 micron to 20 microns,
- the plurality of struts defining a plurality of pores, the construct being 80-98% open pore,
- wherein the construct, in an image of a top or a bottom of the construct, has an open area %, defined as open space between the plurality of struts, and
- wherein the polyurethane matrix in the absence of the conformal silicone coating, in an image along a top or a bottom of the polyurethane matrix, has an open area %, defined as open space between the plurality of matrix struts, and
- wherein the difference between the construct open area % and the matrix open area % is less than 10%.
6 more elements
A method of making a biocompatible open or semi-open celled construct, the method comprising:
- submerging an open or semi-open celled polyurethane foam matrix into a silicone dispersion to expose the polyurethane foam template to the silicone dispersion, the polyurethane foam template comprising a plurality of template struts that define a plurality of template pores,
- allowing the silicone to pass into the plurality of template pores;
- removing at least some of the silicone dispersion from the plurality of template pores;
- curing the silicone to form a conformal silicone coating on the plurality of template struts, at a time subsequent to the curing step, increasing the compliance of the silicone coated template struts compared to a compliance of the silicone coated template struts with the increasing step;
- and
- at a time subsequent to the curing step, forming a hydrophilic layer on the conformal silicone coating to impart wettability, wherein forming a hydrophilic layer on the conformal silicone coating creates a construct including a plurality of construct struts that define a plurality of construct pores.
3 more elements
A biocompatible open or semi-open celled material, comprising:
- an open or semi-open celled construct, comprising
- a plurality of struts including
- a polyurethane template, and
- a conformal silicone layer on the polyurethane template, and
- a hydrophilic coating on the conformal silicone layer adapted to impart wettability to the construct,
- the plurality of struts defining a plurality of pores.
3 more elements
A biocompatible open or semi-open celled material, comprising:
- an open or semi-open celled construct, including,
- a plurality of struts including
- a polyurethane matrix;
- and
- a conformal silicone coating on the polyurethane template and
- the plurality of struts defining a plurality of pores.
3 more elements
A biocompatible open or semi-open celled material, comprising:
- an open or semi-open celled construct, including,
- a plurality of struts including
- a polyurethane matrix;
- and
- a conformal silicone coating on the polyurethane template, and
- the plurality of struts defining a plurality of pores, the construct being 80-98% open pore, wherein the construct, in an image of a top or a bottom of the construct, has an open area %, defined as open space between the plurality of struts, from 20-35%.
3 more elements
A biocompatible open or semi-open celled material, comprising:
- an open or semi-open celled construct, including,
- a plurality of struts including
- a polyurethane matrix;
- and
- a conformal silicone coating on the polyurethane template, and
- the plurality of struts defining a plurality of pores,
- wherein the construct, in an image taken of a cross-section that is orthogonal to a top and a bottom of the construct, has an open area %, defined as open space between the plurality of struts, from 20-35%.
4 more elements
A biocompatible open or semi-open celled material, comprising:
- an open or semi-open celled construct, including,
- a plurality of struts including
- a polyurethane matrix;
- and
- a conformal silicone coating on the polyurethane matrix,
- the plurality of struts defining a plurality of pores, the construct being 80-98% open pore,
- wherein the construct, in an image of a top or a bottom of the construct, has an open area %, defined as open space between the plurality of struts, and
- wherein the polyurethane matrix in the absence of the conformal silicone coating, in an image along a top or a bottom of the polyurethane matrix, has an open area %, defined as open space between the plurality of matrix struts, and
- wherein the difference between the construct open area % and the matrix open area % is less than 10%.
6 more elements
Dependencies are inferred from the claim text.