Foams made by photopolymerization of emulsions
Assignee3M Innovative Properties Company
InventorsKristin LaVelle Thunhorst, Mark David Gehlsen, Robin Edgar Wright, Eric Wayne Nelson, Steven Dean Koecher, Douglas Gold
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Abstract
The invention discloses methods for making foams by photopolymerizing emulsions comprising a reactive phase and a phase immiscible with the reactive phase components. Foams made from water-in-oil emulsions, including high internal phase emulsion are disclosed. Articles and uses for the foams are also described.
Claims25
An open cell cross-linked foam made from an emulsion comprising a reactive phase and an immiscible phase and having a dimensionally long-range macroscopic structure and comprising residue of an emulsifier and of a photoinitiator that absorbs at wavelengths of 300 to 800 nanometers wherein the open cell structure is made of a majority of cells in open communication with each other and having intercellular openings, or interconnected channels, creating at least one open pathway through the foam wherein open areas in the foam correspond to the immiscible phase of the emulsion prior to polymerization and crosslinking of the reactive phase.
An open cell cross-linked foam made from an emulsion comprising a reactive phase and an immiscible phase and containing residue of an emulsifier and no residue of a thermal initiator wherein the open cell structure is made of a majority of cells in open communication with each other and having intercellular openings, or interconnected channels creating at least one open pathway through the foam wherein open areas in the foam correspond to the immiscible phase of the emulsion prior to polymerization and crosslinking of the reactive phase.
An open cell cross-linked foam made from an emulsion comprising a reactive phase and an immiscible phase and having a dimensionally long-range macroscopic structure and a density greater than 0.01 g/cm3 and comprising residue of a photoinitiator that absorbs at wavelengths of 300 to 800 nanometers wherein the open cell structure is made of a majority of cells in open communication with each other and having intercellular openings, or interconnected channels creating at least one open pathway through the foam wherein open areas in the foam correspond to the immiscible phase of the emulsion prior to polymerization and crosslinking of the reactive phase.
An article made from an open cell cross-linked foam made from an emulsion comprising a reactive phase and an immiscible phase and having a dimensionally long-range macroscopic structure and comprising residue of a photoinitiator that absorbs at wavelengths of 300 to 800 nanometers wherein the open cell structure is made of a majority of cells in open communication with each other and having intercellular openings, or interconnected channels creating at least one open pathway through the foam wherein open areas in the foam correspond to the immiscible phase of the emulsion prior to polymerization and crosslinking of the reactive phase and wherein the foam is crosslinked within the voids of a material selected from the group consisting of polymeric, woven, nonwoven, and metals and wherein the article is used as a wound dressing.
An open cell cross-linked foam made from an emulsion comprising a reactive phase and an immiscible phase and having a dimensionally long-range macroscopic structure and comprising residue of a photoinitiator that absorbs at wavelengths of 300 to 800 nanometers, wherein the open cell structure is made of a majority of cells in open communication with each other and having intercellular openings, or interconnected channels creating at least one open pathway through the foam wherein open areas in the foam correspond to the immiscible phase of the emulsion prior to polymerization and crosslinking of the reactive phase and wherein the foam absorbs fluid and wherein the foam density decreases by at least 10% as it absorbs fluid.
An article comprising an open cell cross-linked foam made from an emulsion comprising a reactive phase and an immiscible phase and having a dimensionally long-range macroscopic structure and comprising residue of a photoinitiator that absorbs at wavelengths of 300 to 800 nanometers wherein the open cell structure is made of a majority of cells in open communication with each other and having intercellular openings, or interconnected channels creating at least one open pathway through the foam wherein open areas in the foam correspond to the immiscible phase of the emulsion prior to polymerization and crosslinking of the reactive phase and wherein the article is used for wound dressings.
An article comprising an open cell cross-linked foam having a dimensionally long-range macroscopic structure comprising residue of a photoinitiator that absorbs at wavelengths of 300 to 800 nanometers wherein the article comprises a multilayer structure and wherein two or more layers differ by more than 20% with respect to a property selected from the group consisting of density, and content of a particular component.
An article comprising an open cell cross-linked foam having a dimensionally long-range macroscopic structure comprising residue of a photoinitiator that absorbs at wavelengths of 300 to 800 nanometers wherein the article has two or more regions differing by more than 20% with respect to a property selected from the group consisting of density and content of a particular component.
A process for making a crosslinked polymeric foam comprising:
- a) mixing a reactive phase comprising at least one polymerizable material, at least one crosslinking agent, and at least one emulsifier with at least one photoinitiator and a liquid immiscible with the reactive phase to form an emulsion wherein the immiscible liquid forms a discontinuous or co-continuous phase with the continuous reactive phase;
- b) shaping the emulsion;
- and
- c) exposing the emulsion to actinic radiation to form a crosslinked polymeric foam containing residual immiscible fluid;
- wherein the emulsion is shaped and cured while in contact with a microstructured surface.
Dependencies are inferred from the claim text.