Absorbable polymer blend compositions having enhanced nucleation rates

A medical device comprising an absorbable semi-crystalline polymer blend composition, said blend composition comprising:

• (a) a first amount of a first absorbable polymer having a first crystallization rate, a first molecular weight distribution and a weight average molecular weight from about 50,000 to about 200,000 Daltons;
• and,
• (b) a second amount of a second absorbable ultrahigh molecular weight polymer having a second crystallization rate, a second molecular weight distribution and a weight average molecular weight from about 300,000 to about 3,000,000 Daltons,
• wherein the weight average molecular weight ratio of said first molecular weight distribution to said second molecular weight distribution is at least about one to three, and
• wherein a substantially homogeneous blend of said first and second components is formed in a ratio of between about 99.9/0.1 to about 95/5 weight/weight percent, said substantially homogeneous blend having a crystallization rate greater than each of said first crystallization rate and said second crystallization rate.

A method of making an absorbable semi-crystalline polymer blend, comprising the step of:

• melt processing an absorbable polymer blend, the polymer blend comprising:
• (a) a first amount of a first absorbable polymer having a first crystallization rate, a first molecular weight distribution and a weight average molecular weight from about 50,000 to about 200,000 Daltons;
• and,
• (b) a second amount of a second absorbable ultrahigh molecular weight polymer having a second crystallization rate, a second molecular weight distribution and a weight average molecular weight from about 300,000 to about 3,000,000 Daltons,
• wherein the weight average molecular weight ratio of said first molecular weight distribution to said second molecular weight distribution is at least about one to three, and
• wherein a substantially homogeneous blend of said first and second component is formed in a ratio of between about 99.9/0.1 to about 95/5 weight/weight percent, said substantially homogeneous blend having a crystallization rate greater than each of said first crystallization rate and said second crystallization rate.

A method of making a medical device, comprising the step of:

• forming a medical device by melt-processing or heat treating an absorbable semi-crystalline polymer blend over a temperature range of between about 80° C. to about 260° C., said polymer blend comprising:
• (a) a first amount of a first absorbable polymer having a first crystallization rate, a first molecular weight distribution and a weight average molecular weight from about 50,000 to about 200,000 Daltons;
• and,
• (b) a second amount of a second absorbable ultrahigh molecular weight polymer having a second crystallization rate, a second molecular weight distribution and a weight average molecular weight from about 300,000 to about 3,000,000 Daltons,
• wherein the weight average molecular weight ratio of said first molecular weight distribution to said second molecular weight distribution is at least about one to three, and
• wherein a substantially homogeneous blend of said first and second component is formed in a ratio of between about 99.9/0.1 to about 95/5 weight/weight percent, said substantially homogeneous blend having a crystallization rate greater than each of said first crystallization rate and said second crystallization rate.

A method of manufacturing a polymeric blend, comprising the steps of:

• (a) providing a first amount of a first absorbable polymer having a first crystallization rate, a first molecular weight distribution and a weight average molecular weight from about 50,000 to about 200,000 Daltons;
• (b) providing a second amount of a second absorbable ultrahigh molecular weight polymer having a second crystallization rate, a second molecular weight distribution and a weight average molecular weight from about 300,000 to about 3,000,000 Daltons, wherein the weight average molecular weight ratio of said first molecular weight distribution to said second molecular weight distribution is at least about one to three, and wherein a substantially homogeneous blend of said first and second components is formed in a ratio of between about 99.9/0.1 to about 95/5 weight/weight percent, said substantially homogeneous blend having a crystallization rate greater than each of said first crystallization rate and said second crystallization rate;
• (c) dry blending the first and second amounts to form a blend;
• (d) drying the blend to remove moisture;
• (e) melt blending the blend to homogeneously distribute the second amount of the second polymer in the first amount of the first polymer to form a substantially homogenous blend;
• and,
• (f) drying the homogeneous blend to remove moisture and residual monomer.