U.S. patent application number 12/352820 was filed with the patent office on 2009-05-14 for polyester compositions, methods of manufacturing said compositions, and articles made therefrom.
Invention is credited to Kenneth A. Mazich, Brian J. Swetlin.
Application Number | 20090124956 12/352820 |
Document ID | / |
Family ID | 39253995 |
Filed Date | 2009-05-14 |
United States Patent
Application |
20090124956 |
Kind Code |
A1 |
Swetlin; Brian J. ; et
al. |
May 14, 2009 |
Polyester compositions, methods of manufacturing said compositions,
and articles made therefrom
Abstract
Crosslinked polymer compositions have backbones with first and
second divalent saturated aliphatic moieties, a divalent saturated
aliphatic secondary alcohol moiety, and a trivalent saturated
aliphatic moiety. Hydrolytically labile ester bonds joined together
these moieties. These polyesters may be polycondensation reaction
products of a diol, a triol and a diacid. A molar ratio of the
first divalent saturated aliphatic moiety, the divalent saturated
aliphatic secondary alcohol moiety, and the trivalent saturated
aliphatic moiety to the second divalent saturated aliphatic moiety
is in the range of about 0.85 to about 1.5. Preferably, these
polyesters are non-cytotoxic, biocompatible, bioabsorbable, or
exhibit shape memory behavior with at least one transition
temperature of greater than about 30.degree. C. and less than about
100.degree. C. and most preferably exhibit each of these qualities.
The compositions may be adapted for a wide variety of uses,
including medical applications.
Inventors: |
Swetlin; Brian J.;
(Coatesville, PA) ; Mazich; Kenneth A.; (Newark,
DE) |
Correspondence
Address: |
Richard W. Ellis, Esquire;W.L. Gore & Associates, Inc.
551 Paper Mill Road
Newark
DE
19714-9206
US
|
Family ID: |
39253995 |
Appl. No.: |
12/352820 |
Filed: |
January 13, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11678948 |
Feb 26, 2007 |
7498385 |
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12352820 |
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11541514 |
Sep 28, 2006 |
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11678948 |
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Current U.S.
Class: |
604/8 ; 521/54;
525/437; 525/50; 525/55; 602/42; 604/264; 606/231; 623/1.46 |
Current CPC
Class: |
C08G 18/4241 20130101;
C08G 2110/0008 20210101; C08G 2230/00 20130101; C08G 63/20
20130101; A61L 31/148 20130101; C08G 2280/00 20130101; A61L 31/146
20130101; A61L 31/06 20130101; A61L 31/06 20130101; C08L 67/00
20130101 |
Class at
Publication: |
604/8 ; 525/50;
525/55; 521/54; 525/437; 604/264; 623/1.46; 606/231; 602/42 |
International
Class: |
A61M 1/00 20060101
A61M001/00; C08F 8/00 20060101 C08F008/00; C08J 9/00 20060101
C08J009/00; A61F 2/82 20060101 A61F002/82; A61F 13/00 20060101
A61F013/00; A61L 17/00 20060101 A61L017/00; C08G 63/91 20060101
C08G063/91; A61M 25/00 20060101 A61M025/00 |
Claims
1. An article comprising a composite of at least one fluoropolymer
material and shape memory polymer having at least one transition
temperature of greater than about 30.degree. C. and less than about
100.degree. C., the transition temperature being selected from the
group consisting of a crystalline melting temperature and a glass
transition temperature.
2. The article of claim 1 in which said fluoropolymer material is
selected from the group consisting of: poly(fluorinated
ethylene-co-propylene), poly(tetrafluoroethylene-co-ethylene),
poly(tetrafluoroethylene-co-hexafluoropropylene),
poly(tetrafluoroethylene-co-perfluorobutyl vinyl ether),
poly(tetrafluoroethylene-co-perfluoroethyl vinyl ether),
poly(tetrafluoroethylene-co-perfluoromethyl vinyl ether),
poly(tetrafluoroethylene-co-perfluoropropyl vinyl ether), and
polytetrafluoroethylene.
3. The article of claim 2 in which said fluoropolymer material is a
polytetrafluoroethylene material that has been expanded.
4. The article of claim 3 in which said shape memory polymer is
securely adhered to a microstructure of the expanded
polytetrafluoroethylene material.
5. The article of claim 4 in which said shape memory polymer
substantially fills the pores of the expanded
polytetrafluoroethylene material.
6. The article of claim 1 in which said fluoropolymer material is
in a form selected from the group consisting of: films, fibrous
materials and porous membranes.
7. The article of claim 6 in which said fluoropolymer material
comprises a fibrous material.
8. The article of claim 7 in which the fibrous material is a
nonwoven expanded porous polytetrafluoroethylene material.
9. The article of claim 7 in which the fibrous material is
discontinuously distributed within said shape memory polymer.
10. The article of claim 1 in which said shape memory polymer bonds
together a plurality of fluoropolymer films to form a multilayer
laminate article.
11. The article of claim 10 in which said shape memory polymer
comprises at least two crosslinked polyester compositions, and said
multi-layer laminate article exhibits at least two stages of
controlled shape memory behavior at two predetermined transition
temperatures.
12. The article of claim 1 in which said shape memory polymer
comprises a porous foam material.
13. The article of claim 1 in which the at least one transition
temperature is a crystalline melting temperature of said shape
memory polymer.
14. The article of claim 13 in which the crystalline melting
temperature of said shape memory polymer is greater than about
30.degree. C. and less than about 50.degree. C.
15. The article of claim 14 in which the crystalline melting
temperature of said shape memory polymer is greater than about
30.degree. C. and less than about 45.degree. C.
16. The article of claim 1 in which said fluoropolymer and said
shape memory polymer are biocompatible.
17. The article of claim 16 in which the shape memory polymer is
bioabsorbable.
18. A biocompatible implant comprising the article of claim 16.
19. A composite comprising a porous polymeric membrane in which the
porosity of the membrane is at least partially filled with a
crosslinked aliphatic polyester shape memory polymer and in which
the polyester shape memory polymer has at least one transition
temperature of greater than about 30.degree. C. and less than about
100.degree. C.
20. The composite of claim 19 in which said porous polymeric
membrane comprises a fluoropolymer.
21. The composite of claim 20 in which said fluoropolymer comprises
expanded polytetrafluoroethylene.
22. The composite of claim 19 in which said porous polymeric
membrane is bioabsorbable.
23. The composite of claim 22 in which said porous polymeric
membrane comprises a poly(glycolide-co-trimethylenecarbonate)
non-woven material.
24. The composite of claim 19 in which the at least one transition
temperature of said shape memory polymer is greater than about
30.degree. C. and less than about 50.degree. C.
25. The composite of claim 24 in which the at least one transition
temperature of said shape memory polymer is greater than about
30.degree. C. and less than about 45.degree. C.
26. A biocompatible implant comprising the composite of claim
19.
27. A biocompatible implant comprising a composite of at least two
polymer materials and in which at least one of the polymer
materials is bioabsorbable and the implant exhibits shape memory
behavior upon heating to at least one transition temperature of
greater than about 30.degree. C. and less than about 100.degree.
C.
28. The biocompatible implant of claim 27 in which the one of the
polymer materials that is bioabsorbable has a residual acidity in
concentrations of greater than about 0.0001 meq. acid/gram and less
than about 1.0 meq. acid/gram.
29. The biocompatible implant of claim 28 in which the residual
acidity is less than about 0.5 meq. acid/gram.
30. The biocompatible implant of claim 29 in which the residual
acidity is less than about 0.3 meq. acid/gram measured by
titration.
31. The biocompatible implant of claim 27 in which both of the two
polymer materials are bioabsorbable.
32. The biocompatible implant of claim 27 in which one of the two
polymer materials is a shape memory foam.
33. The biocompatible implant of claim 27 in which the at least one
transition temperature corresponds to a crystalline melting
temperature of one of the two polymer materials.
34. The biocompatible implant of claim 33 in which the crystalline
melting temperature is greater than about 30.degree. C. and less
than about 50.degree. C.
35. The biocompatible implant of claim 34 in which one of the two
polymer materials is a fibrous aliphatic polyester.
36. The biocompatible implant of claim 35 in which the fibrous
aliphatic polyester is selected from the group consisting of:
poly(glycolide-co-trimethylene carbonate), poly(L-lactide),
poly(D-lactide), poly(D,L-lactide), poly(glycolide-co-lactide) and
poly(.epsilon.-caprolactone).
37. The biocompatible implant of claim 35 in which the fibrous
aliphatic polyester defines a structure having pores and the other
one of the two polymer materials is a bioabsorbable shape memory
polymer is at least partially disposed within some of the
pores.
38. The biocompatible implant of claim 37 in which the
bioabsorbable shape memory polymer is a crosslinked aliphatic
polyester.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/678,948 filed Feb. 26, 2007, which is a
divisional of U.S. patent application Ser. No. 11/541,514, filed
Sep. 28, 2006.
FIELD OF THE INVENTION(S)
[0002] The present application relates to polymer compositions,
specifically to polyesters, and more specifically to crosslinked
polyesters that are the products of polycondensation reactions of a
diol, a triol and a diacid, methods of manufacturing said
compositions, and articles made therefrom.
BACKGROUND OF THE INVENTION(S)
[0003] Biocompatible and bioabsorbable in vivo synthetic polymers
are known for use in the manufacture of implantable medical
devices. Many such bioabsorbable polymers belong to the polyester
family. For example, aliphatic polyesters have been used in drug
delivery systems.
[0004] Known biodegradable polyester polymer/copolymer materials
include polydioxanone (PDS), polyglycolic acid (PGA), poly-L-lactic
acid (PLA), and copolymers of polyglycolic acid and either L-lactic
acid or trimethylene carbonate (TMC).
[0005] Linear polyesters may be synthesized by ring opening
polymerization of cyclic esters or lactones, or by polycondensation
of one or more difunctional monomers. Polycondensation of
difunctional monomers include the esterification of diacid
chlorides and diols, or the ester exchange reaction of diesters and
diols. Crosslinked polyesters can be formed by including in the
polycondensation reaction monomers with functionalities greater
than two.
[0006] U.S. Pat. No. 1,779,367 discloses condensation reaction
products of certain higher polybasic acids and polyhydric alcohols,
notably glycerol. In one example, 1 mole equivalent gylcerol and
1.5 mole equivalents sebacic acid are reacted.
[0007] U.S. Pat. No. 2,012,267 discloses alkylene ester reaction
products of polybasic acids. These esters are said to be formed by
the esterification of dibasic acids and glycols of the formula:
OH(CH.sub.2).sub.mOH,
where "m" is an integer greater than 2. In example 5, poly(ethylene
sebacate) is prepared from 67.3 g of sebacic acid and 21.7 g of
ethylene glycol.
[0008] U.S. Pat. No. 5,098,776 discloses fibrous sheets having
shape memory properties. The sheet comprises a natural or synthetic
fiber and a layer formed by applying a powder of shape memory
polymer. The shape memory polymer may be a urethane polymer, a
styrene butadiene polymer, a crystalline diene polymer, and a
norbornane polymer. To impart shape memory properties, a powder of
shape memory polymer is applied to a part of the sheet with the aid
of adhesive.
[0009] U.S. Pat. No. 5,889,140 discloses molded articles made from
crosslinkable polylactone-based compositions having
biodegradability and shape memorizable properties. The compositions
are made from 100 parts by weight of polylactone (A) having a
number average molecular weight of 10,000 to 300,000 and 0.1 to 30
parts by weight of crosslinkable monomer (B). The crosslinkable
polylactone-based composition is crosslinked by irradiating active
energy radiation or by heating at 120.degree. C. to 250.degree.
C.
[0010] U.S. Pat. No. 6,160,084 discloses biodegradable shape memory
polymers. In one embodiment, the compositions contain hard and soft
segments. The hard segments have a higher transition temperature
than the soft segments. The hard segments have a transition
temperature of between -30.degree. C. and 270.degree. C. Either the
hard or soft segments are crosslinkable.
[0011] U.S. Pat. Publ. No. 2003/0118692 discloses biodegradable
polymer condensation products of glycerol and diacid (e.g., sebacic
acid). The degradation rate is reputed by this publication to be
adjustable by modifying crosslink density. The molar ratio of
glycerol to the diacid disclosed may be between (1 and 1.5):1. This
publication reports the manufacture of a poly(glycerol-sebacate) by
polycondensation of equi-molar amount of glycerol and sebacic acid.
The publication also reports that the resulting polymer has two
crystallization temperatures at -52.14.degree. C. and
-18.50.degree. C., has two melting temperatures at 5.23.degree. C.
and 37.62.degree. C., and is totally amorphous at 37.degree. C. The
disclosed polymer is suggested for use as a tissue engineering
construct, or in other medical and non-medical applications. This
publication does not report any shape memory properties for this
material.
[0012] Chinese Pat. Publ. No. 1 640 909 A discloses biodegradable
ternary aliphatic polyester elastomers. An esterification reaction
is carried out between a dibasic acid and a diol to form a
low-molecular weight linear prepolymer. In this reaction, the molar
ratio of the dibasic acid to diol is between (1.5 and 3.5):1. An
esterification crosslinking reaction then is carried out between
that linear prepolymer and a monomeric polyol. This patent
publication does not report any shape memory properties for this
material, and instead describes the resulting polyester as an
elastomer.
SUMMARY OF THE INVENTION(S)
[0013] Crosslinked polymer compositions, specifically crosslinked
polyesters, methods of manufacturing said compositions, and
articles made therefrom are described.
[0014] In one aspect, the present application provides a
crosslinked polycondensation product of a polyol and at least one
saturated linear aliphatic diacid or derivative thereof. The polyol
includes saturated aliphatic triol and saturated aliphatic diol.
Preferably, the polyol includes glycerol and one of: ethylene
glycol, 1,3 propanediol and 1,4 butanediol. Preferably, the
aliphatic diacid or derivative thereof is sebacic acid. A molar
ratio of moles saturated aliphatic triol to moles total polyol is
in the range of about 0.2 to about 0.8. A molar ratio of moles
total polyol to moles diacid is in the range of about 0.85 to about
1.5.
[0015] In another aspect, the present application provides a
polymer composition with a backbone having a first and a second
divalent saturated aliphatic moiety, a divalent saturated aliphatic
secondary alcohol moiety, a trivalent saturated aliphatic moiety,
and ester linkages between the moieties. A molar ratio of the sum
of (1) a number of moles of the first divalent saturated aliphatic
moiety, (2) a number of moles of the divalent saturated aliphatic
secondary alcohol moiety, and (3) a number of moles of the
trivalent saturated aliphatic moiety to a number of moles of the
second divalent saturated aliphatic moiety is in the range of about
0.85 to about 1.5.
[0016] In another aspect, the present application provides a method
of manufacturing a crosslinked polyester composition via a
polycondensation reaction of (a) polyol, comprising saturated
aliphatic triol, and saturated aliphatic diol, and (b) a linear
aliphatic diacid or derivative thereof (e.g., a diester of
saturated linear aliphatic diacid, or a diacyl halide of a
saturated linear aliphatic diacid), or mixtures thereof. Component
(a), the polyol, may comprise glycerol and ethylene glycol, and
preferably is present in a molar ratio of moles triol to moles
total polyol of between about 0.20 and 0.80. Component (b), the
diacid or diacid derivative, may comprise sebacic acid, and
preferably is present in a molar ratio of polyol to diacid of
between about 0.85 to about 1.5.
[0017] In yet another aspect, the present application provides an
article having a crosslinked polyester composition, which
preferably exhibits shape memory properties, and more preferably
has at least one transition temperature of greater than about
30.degree. C. and less than about 100.degree. C.
[0018] In still another aspect, the present application provides a
porous article or foam, e.g., foamed or sponge-like porous material
having cell walls comprising a crosslinked polyester composition.
Preferably, the foamed or sponge-like porous material exhibits
shape memory properties, and more preferably has at least one
transition temperature of greater than about 30.degree. C. and less
than about 100.degree. C.
[0019] In yet still another aspect, the present application
provides a composite having a macroscopic combination of a
crosslinked polyester composition with at least one other material.
Preferably, the other material is a film material, a fibrous
material, a porous membrane material, or combinations thereof.
Preferably, the crosslinked polyester composition, the composite or
both exhibit shape memory properties, and more preferably, the
crosslinked polyester composition has at least one transition
temperature of greater than about 30.degree. C. and less than about
100.degree. C.
[0020] In another aspect, the present application provides a
composite having a macroscopic combination of
polytetrafluoroethylene (PTFE) and a shape memory polymer.
Preferably, the PTFE is expanded PTFE (ePTFE). Preferably, the
shape memory polymer exhibits shape memory behavior upon heating to
at least one transition temperature of greater than about
30.degree. C. and less than about 100.degree. C. More preferably,
the shape memory polymer is a crosslinked polyester
composition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic representation of an exemplary closed
cell porous foam product;
[0022] FIG. 2 is a schematic representation of an exemplary
composite construction with imbibed ePTFE;
[0023] FIG. 3 is a schematic representation of an exemplary
composite construction having ePTFE coated with crosslinked polymer
composition on one side;
[0024] FIG. 4 is a schematic representation of an exemplary
composite construction having ePTFE coated with crosslinked polymer
composition on two sides;
[0025] FIG. 5 is a schematic representation of an exemplary
composite construction having ePTFE coated with crosslinked polymer
composition on one side and imbibed into the ePTFE;
[0026] FIG. 6 is a schematic representation of an exemplary porous,
laminated foam product;
[0027] FIG. 7 is a longitudinal cross-sectional view of an
exemplary aneurysm repair device;
[0028] FIG. 8 is an axial cross-sectional view of an exemplary
aneurysm repair device;
[0029] FIG. 9 is a schematic representation of an exemplary
aneurysm repair device after expansion of the foam crosslinked
polymer composition;
[0030] FIG. 10 is a schematic representation of an exemplary
intraluminal delivery device during introduction into the
lumen;
[0031] FIG. 11 is a schematic representation of an exemplary
intraluminal delivery device after expansion of part of the shaft
member;
[0032] FIG. 12 is a schematic representation of an exemplary
intraluminal delivery device as the introducer is removed;
[0033] FIG. 13 is a schematic representation of an exemplary
intraluminal delivery device after the introducer is removed and
the plug expands;
[0034] FIG. 14 is a schematic representation of an exemplary
intraluminal delivery device after the shaft member is removed;
[0035] FIG. 15 is a schematic representation of an exemplary
deployment means for an endoluminal device in an expanded or
deployed shape;
[0036] FIG. 16 is a schematic representation of an exemplary
deployment means for an endoluminal device in reduced or undeployed
shape;
[0037] FIG. 17 is a temperature and water evolution history for the
polymerization reaction of Example 1;
[0038] FIG. 18 are results of differential scanning calorimetry
(DSC), mechanical and shape recovery experiments for the reaction
product of Example 1;
[0039] FIG. 19 is a scanning electron microscope view of an
exemplary porous composition of Example 20; and
[0040] FIG. 20 is a graph of dimension change and temperature for
the exemplary composite of Example 24.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] Certain exemplary embodiments of the present invention(s)
will be described below and detailed in the examples and with
reference to the accompanying drawings. The present invention(s)
may, however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein.
[0042] As used throughout the specification, the following terms
shall have the following meanings, unless the context clearly
indicates otherwise.
[0043] By "Bioabsorbable" is meant a material that is capable of
being degraded over time when placed in a living body (e.g.,
through enzymatic, hydrolytic or other chemical reactions) into
products which are metabolized, assimilated or excreted from the
body.
[0044] By "Biocompatible" is meant a material that invokes no
adverse tissue reactions at the implant site in a majority of
mammals after implantation. Biocompatibility may be evaluated with
reference to International Standards Organization (ISO) Standard
No. 10993 Part 6: Tests for local effects after implantation, First
Ed., July, 1994.
[0045] By "medical device" is meant an instrument, apparatus,
contrivance, implant, implement, machine, or other similar or
related article, including, but not limited to, any accessory,
component, kit or part, which is used in the cure, diagnosis,
mitigation, prevention, or treatment of disease, in man or other
animals, or intended to affect the structure or any function of the
body of man or other animals. Such medical devices include, but are
not limited to, aneurysm repair devices, cannulae, catheters,
endoprostheses, hernia plugs, implants, occlusive devices,
periodontal repair materials, pledget materials, prostheses, septal
occlusive devices, shunts, stents, surgical repair patches,
sutures, tubes, vascular grafts, vascular occlusion devices,
vascular patches, wound dressings and the like.
[0046] By "shape memory behavior" is meant that a material capable
of storing or memorizing a first shape so that the polymer may be
deformed to and maintains a second shape until appropriately
stimulated (e.g., by heating above a transition temperature), after
which the polymer tends to revert from the second shape to the
first shape. It also may be possible to stimulate shape memory
behavior with other stimuli, e.g., by changes in pH, electrical
stimuli, light stimuli.
[0047] By "transition temperature" is meant a temperature range
where a material is subject to a phase transition, which, in the
case of polymeric materials, means the polymeric materials are
completely amorphous above the transition temperature and may be
crystalline or semi-crystalline below the transition temperature.
The phase change can be determined by a conventional Differential
Scanning Calorimetry (DSC) scan of the material.
[0048] Backbones of the crosslinked polymer compositions described
below are comprised of four monomeric repeating units. A first
monomeric repeating unit is a divalent aliphatic moiety. A second
monomeric repeating unit is a divalent aliphatic alcohol moiety. A
third monomeric repeating unit is a trivalent aliphatic moiety. A
fourth monomeric repeating unit is another divalent aliphatic
moiety, which may be the same or different from the first monomeric
repeating unit.
[0049] These monomeric repeating units are joined together by
hydrolytically labile ester bonds. Alternatively, other
hydrolytically labile bonds, under physiological conditions, may
join the monomer repeating units including, but not limited to,
amide, carbonate, thioamide, thioester, and urethane linkages,
among others.
[0050] The amounts of the monomeric repeating units and the ester
linkages may be varied to achieve crosslinked polyester
compositions having properties appropriate for various
applications. Preferably, the first, second and third monomeric
repeating units are, independently, present in the final polymer
composition in an amount of about 4 to about 30 mol %. Preferably,
the fourth monomeric repeating unit is present in the final polymer
composition in an amount about 20 to about 30 mol %. Preferably,
the ester linkages are present in the final polymer composition in
an amount of about 35 to about 55 mol %.
[0051] The first monomeric repeating unit (R.sub.1) has the
formula:
--[CH.sub.2].sub.a--
where a is an integer between 2 and 35, preferably between 2 and 20
and more preferably between 2 and 10.
[0052] The second monomeric repeating unit (R.sub.2) has the
formula:
##STR00001##
where b and c are, independently, integers between 1 and 35,
preferably between 1 and 20 and more preferably between 1 and
10.
[0053] The third monomeric repeating unit (R.sub.3) has the
formula:
##STR00002##
where d and e are, independently, integers between 1 and 35,
preferably between 1 and 20 and more preferably between 1 and
10.
[0054] The fourth monomeric repeating unit (R.sub.4) has the
formula:
--[CH.sub.2].sub.f--
where f is an integer between 2 and 35, preferably between 2 and 20
and more preferably between 2 and 10.
[0055] Most preferably, the value of integer a is 2, the values of
integers b, c, d and e are identical and are 1, and the value of
integer f is 8.
[0056] A molar ratio, .phi., is given by the formula:
.PHI. = [ molesR 2 + molesR 3 ] [ molesR 1 + molesR 2 + molesR 3 ]
##EQU00001##
[0057] .phi. is preferably in the range of 0.20 to 0.80. When the
crosslinked polymer compositions are random polymers, .phi. is more
preferably 0.20.ltoreq..phi..ltoreq.0.65, and most preferably
0.20.ltoreq..phi..ltoreq.0.50. When the crosslinked polymer
compositions are non-random polymers, .phi. is more preferably
0.50.ltoreq..phi..ltoreq.0.80.
[0058] A molar ratio, .beta., is given by the formula:
.beta. = [ molesR 1 + molesR 2 + molesR 3 ] [ molesR 4 ]
##EQU00002##
[0059] .beta. is preferably in the range of 0.85 to 1.5, more
preferably 0.87.ltoreq..beta..ltoreq.1.35, and most preferably
0.9.ltoreq..beta..ltoreq.1.2.
[0060] A density, .rho., of the crosslinked polymer compositions
(exclusive of additives) is in the range of 0.05 grams per cubic
centimeter (g/cc) to 1.50 g/cc (exclusive of any additives). The
crosslinked polymer compositions may be made into a foamed or
sponge-like porous material by, for example combining the
crosslinked polymer compositions with a gas, such as air. The
foamed or sponge-like materials have a density less than about 0.80
g/cc, preferably have a density in the range of about 0.1 g/cc to
about 0.3 g/cc.
[0061] Preferably, the crosslinked polymer compositions have
residual acidity in concentrations of greater than about 0.0001
milliequivalents of acid per gram of composition (meq. acid/gram)
and less than about 1.0 meq. acid/gram or less, more preferably in
concentrations less than about 0.5 meq. acid/gram, and most
preferably in concentrations less than about 0.3 meq. acid/gram
measured by titration.
[0062] Residual acid, when present in the crosslinked polymer
compositions, provides ion exchange properties, and thus the
crosslinked polymer compositions may form ionic salts with
cationic, polycationic and zwitterionic species. These cationic,
polycationic and zwitterionic species include, but are not limited
to, aluminum ions, amino acids, amino sugars, ammonium ions, barium
ions, calcium ions, chitin, chitosan, copper ions, ferric ions,
ferrous ions, magnesium ions, peptides, polyethyleneimine,
polypeptides, potassium ions, primary amino compounds, quaternary
amine compounds, quaternary ammonium compounds, secondary amino
compounds, sodium ions and combinations thereof.
[0063] Residual acid groups and residual hydroxyl groups also may
be reacted with organic compounds, bio-organic compounds and
pharmaceutical compounds to modify the biological properties of the
compositions. Conjugation reactions may modify the biological
properties of the crosslinked polymer compositions. Such biological
properties include, but are not limited to, angiogenesis
properties, anti-scarring properties, bactericidal properties,
blood coagulation properties, cellular adhesion properties,
cellular growth properties, cellular migration properties, cellular
morbidity properties, cellular targeting properties, infection
prevention properties, thrombogenic properties, tissue generation
properties, tissue in-growth properties, and wound healing
properties.
[0064] Residual acid groups and residual hydroxyl groups may be
quantified by various well known analytical procedures. For
example, residual unreacted hydroxyl groups will be apparent in the
infrared spectra of the crosslinked polymer compositions. Titration
methods also may be used to quantify said residual unreacted
hydroxyl and carboxylic acid groups. For example, residual
unreacted carboxylic acid groups of the crosslinked polymer
compositions may be quantified by titration with a strong base,
such as potassium hydroxide.
[0065] The Young's modulus at 22.degree. C. preferably is greater
than 2.5 Megapascals (MPa). Where the crosslinked polymer
composition is a random polymer, the Young's modulus is more
preferably greater than about 6.0 MPa, and most preferably greater
than about 40 MPa. Where the crosslinked polymer composition is
non-random, the Young's modulus is more preferably greater than
about 5.0 MPa and most preferably greater than about 6.0 MPa. The
Young's modulus is lower at 37.degree. C. than at 22.degree. C. The
elastic modulus at 37.degree. C. preferably is in the range of
about 0.1 to about 200 MPa, more preferably is in the range of
about 1 to about 25 MPa, and most preferably is in the range of
about 2.5 to about 10 MPa.
[0066] The crosslinked polymer compositions degrade via hydrolysis.
Hydrolysis may be catalyzed or not. Hydrolysis catalysts may
include, but are not limited to, enzymes (particularly lipases and
esterases). Hydrolysis may be demonstrated in water, saline, blood
serum or aqueous solutions of enzymes. Hydrolysis may be affected
by biological life forms such as bacteria, fungi, and molds.
Hydrolysis is also affected in-vivo, such as when the crosslinked
polymer compositions are implanted in a mammal. Hydrolysis is
accompanied by weight loss. Hydrolysis leads to the production of
various reaction products including diols, triols and diacids from
which the crosslinked polymer compositions may have been produced.
These reaction products may be further degraded, metabolized,
assimilated or excreted in-vivo. Preferably, the crosslinked
polymer compositions are biocompatible, bioabsorbable and/or
non-cytotoxic.
[0067] The chain microstructural sequence, or "order," of the units
may be random or non-random. These microstructural sequences can
affect properties of the crosslinked polymer compositions.
Non-random microstructural sequences may be described as block or
multi-block chain microstructures. The chain order may be
characterized by various analytical methods, such as nuclear
magnetic resonance (NMR) spectroscopy.
[0068] The crosslinked polymer compositions may be homogeneous or
phase separated (i.e., characterized by a macroscopic topology or
structural morphology where chains rich in a particular monomeric
repeating unit are spatially segregated from chains rich in another
monomeric repeating unit). Various analytical methods may be used
to characterize whether the crosslinked polymer compositions are
homogenous or phase separated. These methods include, but are not
limited to, calorimetry, dilatometry, light scattering
spectroscopy, microscopy, and thermal mechanical analysis.
[0069] The crosslinked polymer compositions may be amorphous or
semicrystalline at temperatures greater than about 20.degree. C. to
less than about 25.degree. C. Preferably, the crosslinked polymer
composition exhibits crystallization upon cooling from a
temperature of about 100.degree. C. to a temperature of about
20.degree. C. at a rate of 2.degree. C./min.
[0070] Preferably, the crosslinked polymer compositions are
semicrystalline at temperatures in the range of greater than about
20.degree. C. to less than about 25.degree. C. In these preferred
embodiments, the volume fraction or weight fraction of the
crystalline phases may be in the range 0.05 to 0.95. Various well
known analytical methods (e.g., calorimetry, dilatometry, X-ray
diffraction and microscopy) may be used to characterize whether
compositions are crystalline/semicrystalline.
[0071] Those crosslinked polymer compositions that are
semicrystalline at temperatures in the range of greater than about
20.degree. C. to less than 25.degree. C., are preferably totally
amorphous at temperatures greater than near physiological
temperatures, e.g., above temperatures greater than about
30.degree. C. When the crosslinked polymer compositions are totally
amorphous at near physiological temperatures, this enables, among
other things, shape memory behavior stimulation by body heat.
[0072] More preferably, such crosslinked polymer compositions are
totally amorphous above temperatures greater than about 35.degree.
C., and most preferably are totally amorphous above 35.degree. C.
and less than about 100.degree. C. The higher temperature(s) may be
advantageous for simplifying storage requirements and preventing
unintentional activation of shape memory behavior. In this aspect,
the shape memory behavior may be stimulated by external heat and
other energy sources, as described more fully below. The
semicrystalline to totally amorphous transition temperature of the
crosslinked polymer compositions is a function of the reactants
chosen, their relative proportion and the synthetic process path
chosen.
[0073] Preferably, the crosslinked polyester compositions have at
least one transition temperature of greater than about 30.degree.
C. and less than about 100.degree. C., more preferably greater than
about 30.degree. C. and less than about 50.degree. C., and most
preferably greater than about 30.degree. C. and less than about
45.degree. C.
[0074] Preferably, the crosslinked polymer compositions exhibit
shape memory behavior. These compositions maintain dimensional
change in the absence of external forces in their semicrystalline
state. If the material is semicrystalline when deformed, for
example in cold drawn deformation, the shape is maintained without
substantial change in crystallinity. If the material is amorphous
when deformed, the deforming force is maintained while the shape
memory material is caused to partially crystallize, by cooling for
example.
[0075] Upon application of a stimulus, the shape change is at least
partially recovered. The stimulus directly or indirectly induces a
change in crystallinity. For example, the stimulus may include
heat. The resulting temperature increase reduces crystallinity. In
the crosslinked polymer compositions exhibiting shape memory
behavior, this transformation may occur at any temperature greater
than about 35.degree. C. to less than about 100.degree. C. The
shape memory behavior may be manifested by a change in at least one
dimension of the polymeric material in response to stimulus, or if
the material is restrained, a change in the force necessary to
maintain the shape of the material in at least one dimension upon
application of stimulus, or both.
[0076] The crosslinked polymer compositions can be sterilized.
Preferred sterilization methods include, but are not limited to,
autoclave, ethylene oxide and gamma radiation. The most preferred
sterilization method is gamma radiation. The preferred gamma
radiation dosage is about 25 kiloGray (kGy) or less.
[0077] The crosslinked polymer compositions may contain various
further ingredients, which may be added to the reactants before
polymerization, during polymerization or after polymerization is
completed. The quantity of such further ingredients optionally
added to the crosslinked polymer compositions will preferably
comprise less than about 25% of the composition by volume. More
preferably, the quantity of said further ingredients comprises less
than about 15% of the composition by volume. Most preferably, such
further ingredients comprise less than about 5% of the composition
by volume. The various further ingredients may be fillers or
nano-materials (e.g., have at least one dimension which is 100
nanometers or less).
[0078] For example, ceramic, inorganic, metallic, organic,
organometallic, pharmaceutical, and polymeric additives may be
optionally added to the crosslinked polymer compositions as desired
to modify the crosslinked polymer composition's acoustic
properties, anti-scarring properties, bio-degradation properties,
biological properties, color, crystallization kinetics, density,
disease prevention properties, disease treatment properties,
electrical properties, mechanical properties, optical properties,
photo-degradation properties, processing behavior, surface
properties, thermo-degradation properties,
thermo-oxidative-degradation properties, wound healing properties,
and combinations thereof.
[0079] Inorganic or metallic radio-opaque particles are one such
additive, and may be dispersed into the crosslinked polymer
compositions. Said radio-opaque particles include, but are not
limited to, barium sulfate, gold, platinum, silver and combinations
thereof. Preferably, said radio-opaque particles are present at a
volume fraction less than about 0.30. More preferably, said
radio-opaque particles are present at a volume fraction less than
about 0.20. Most preferably, said radio-opaque particles are
present at a volume fraction less than about 0.10.
[0080] Dyes or pigments are another additive that may be added to
the crosslinked polymer compositions. By altering the color of the
crosslinked polymer compositions, the compositions may be caused to
absorb light energy (e.g., laser light) and thereby increase local
temperature sufficient to selectively stimulate a transformation
from the metastable state to the original or default shape, i.e.,
shape memory behavior. This may be advantageous where the
crosslinked polymer compositions are desired to be deployed in
small spaces, which may only be accessible via optical fibers
(which can transmit light to the crosslinked polymer compositions).
Alternatively, the crosslinked polymer compositions may be colored
so that discrete regions have different light absorption
characteristics than other regions. This permits different regions
of the crosslinked polymer compositions to be activated utilizing
light sources with discrete wavelengths that correspond to the
particular absorption band.
[0081] Isocyanate or diisocyanate compounds are yet another
additive. These compounds may be included in the crosslinked
polymer composition to modify the density and to produce a foamed
or sponge-like article. Nucleating agents are still another
additive, which may be used to modify the crystallization kinetics
of the crosslinked polymer compositions. A hydrophilic coating may
be applied to the surface of articles prepared from the crosslinked
polymer compositions to modify the surface properties. Combinations
of various additives also may be used.
[0082] Where the labile bonds are ester bonds, the composition is a
crosslinked aliphatic polyester. In that case, the structure of the
backbone may consist essentially of linked ester units, A, B, and
C. The linked ester units are of the formula:
##STR00003##
where R.sub.1, R.sub.2, R.sub.3 and R.sub.4 are given by the
formulas set forth above.
[0083] Such crosslinked aliphatic polyester may be the
polycondensation reaction products of monomers containing hydroxyl
groups and carboxylic acid groups. In these reactions, polymer
chain growth proceeds by condensation reactions between molecules
of all degrees of polymerization. For example, a diol with two
hydroxyl groups, a diacid with two carboxylic acid groups, and a
triol with three hydroxyl groups may be used. In that embodiment,
ester unit A is a condensation product of an aliphatic diol and a
linear aliphatic dicarboxylic acid, and ester units B and C are
condensation products of aliphatic triols and linear aliphatic
dicarboxylic acids.
[0084] It should be understood that alternatively, the polyester
also may be the polycondensation reaction product of a diol with
two hydroxyl groups, a diacid with two carboxylic acid groups and a
triacid with three carboxylic acid groups.
[0085] In embodiments made from a diol, a diacid and a triol,
R.sub.1 is a linear sequence of covalently bonded methylene groups
originating from an unsubstituted linear aliphatic diol. The linear
sequence of methylene groups is covalently bonded at one end to an
ester group. At the other end, the linear sequence of methylene
groups may be covalently bonded either to an ester group or to a
primary hydroxyl group. The ester group(s) is the reaction product
of a primary hydroxyl group of an unsubstituted linear aliphatic
diol and a carboxylic acid group of a linear aliphatic dicarboxylic
acid. The primary hydroxyl group originates from an unsubstituted
linear aliphatic diol.
[0086] In embodiments made from a diol, a diacid and a triol,
R.sub.2 is a linear sequence of covalently bonded carbon atoms
originating from a linear aliphatic triol. The terminal carbon
atoms of the linear sequence are each covalently bonded to two
hydrogen atoms. The terminal carbon atom at one end of the linear
sequence also is covalently bonded to an ester group, and the
terminal carbon atom at the other end either is covalently bonded
to an ester group or to a primary hydroxyl group. An intermediate
carbon atom of the linear sequence of covalently bonded carbon
atoms (e.g., the middle carbon atom when R.sub.2 has three
covalently bonded carbon atoms) is covalently bonded to a hydrogen
atom and to a secondary hydroxyl group. The ester group(s) is the
reaction product of a primary hydroxyl group of a linear aliphatic
triol and a carboxylic acid group of a linear aliphatic
dicarboxylic acid. The primary hydroxyl group originates from a
linear aliphatic triol.
[0087] Also in embodiments made from a diol, a diacid and a triol,
R.sub.3 is a branched or crosslinked moiety. It is a linear
sequence of covalently bonded carbon atoms originating from a
linear aliphatic triol. The terminal carbon atoms of said linear
sequence are each covalently bonded to two hydrogen atoms. Each of
the terminal carbon atoms is covalently bonded to an ester group.
These ester groups are the reaction products of a primary hydroxyl
group of a linear aliphatic triol and a carboxylic acid group of a
linear aliphatic dicarboxylic acid. An intermediate carbon atom of
said linear sequence of carbon atoms (e.g., the middle carbon atom
when R.sub.3 has three covalently bonded carbon atoms) is
covalently bonded to one hydrogen atom and to one ester group. The
ester group is the reaction product of a secondary hydroxyl group
of a linear aliphatic triol and a carboxylic acid group of a linear
aliphatic dicarboxylic acid.
[0088] Also in embodiments made from a diol, a diacid and a triol,
R.sub.4 is a linear sequence of covalently bonded methylene groups
originating from a linear aliphatic dicarboxylic acid. The linear
sequence of covalently bonded methylene groups also is covalently
bonded at one end of said sequence to a) an ester group that is the
reaction product of a carboxylic acid group of a linear aliphatic
dicarboxylic acid and a primary hydroxyl group of a unsubstituted
linear aliphatic diol, or b) an ester group that is the reaction
product of a carboxylic acid group of a linear aliphatic
dicarboxylic acid and a primary hydroxyl group of a aliphatic
triol, or c) an ester group that is the reaction product of a
carboxylic acid group of a linear aliphatic dicarboxylic acid and a
secondary hydroxyl group of a aliphatic triol. The linear sequence
of covalently bonded methylene groups also is covalently bonded at
the other end of said sequence to a) a carboxylic acid group
originating from said linear aliphatic dicarboxylic acid, or b) an
ester group that is the reaction product of a carboxylic acid group
of a linear aliphatic dicarboxylic acid and a primary hydroxyl
group of a preferred unsubstituted linear aliphatic diol, or c) an
ester group that is the reaction product of a carboxylic acid group
of a linear aliphatic dicarboxylic acid and a primary hydroxyl
group of a aliphatic triol, or d) an ester group that is the
reaction product of a carboxylic acid group of a linear aliphatic
dicarboxylic acid and a secondary hydroxyl group of a aliphatic
triol.
[0089] Linear aliphatic diols include, but are not limited to,
unsubstituted linear aliphatic diols, such as 1,2-ethanediol (i.e.,
ethylene glycol), 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol,
1,6-hexanediol, 1,7-heptanediol, 1,8-octanediol, 1,9-nonanediol,
1,10-decanediol and combinations thereof. Preferred unsubstituted
linear aliphatic diols include 1,2-ethanediol, 1,3-propanediol,
1,4-butanediol. 1,2-ethanediol is most preferred.
[0090] Linear aliphatic triols include, but are not limited to,
1,2,3-trihydroxypropane, butane-1,2,4-triol and combinations
thereof. Although other aliphatic triols may be used, a preferred
aliphatic triol is 1,2,3-trihydroxypropane (i.e., glycerol).
[0091] Linear aliphatic dicarboxylic acids include, but are not
limited to, 1,4-butanedioic acid, 1,5-pentanedioic acid,
1,6-hexanedioic acid, 1,7-heptanedioic acid, 1,8-octanedioic acid,
1,9-nonanedioic acid, 1,10-decanedioic acid, 1,11-unedecanedioic
acid, 1,12-dodecanedioic acid and combinations thereof. More
preferred linear aliphatic dicarboxylic acids are 1,4-butanedioic
acid (i.e., succinic acid), 1,6-hexanedioic acid (i.e., adipic
acid) and 1,10-decanedioic acid (i.e., sebacic acid). A most
preferred linear aliphatic dicarboxylic acid is sebacic acid.
Preferably, the aliphatic dicarboxylic acids are unsubstituted.
[0092] The dicarboxylic acids may be used in the form of one or
more of their corresponding diester derivatives, particularly their
dimethanol or diethanol ester derivatives. The dicarboxylic acids
also may be used as one or more of their corresponding diacyl
halide derivatives, particularly their diacyl chloride derivatives.
The dicarboxylic acid may be used as a corresponding anhydride. For
example, succinic anhydride may be used instead of 1,4-butanedioic
acid.
[0093] In addition to the aforementioned preferred unsubstituted
linear aliphatic diols, linear aliphatic triols and linear
aliphatic dicarboxylic acids, the crosslinked polymer compositions
may include linear aliphatic .alpha.,.omega.-hydroxyacids or their
corresponding cyclic dimers, such as glycolic acid, glycolide,
lactic acid, lactide, .beta.-hydroxypropanoic acid,
.gamma.-hydroxybutanoic acid and combinations thereof. Preferably,
said linear aliphatic .alpha.,.omega.-hydroxyacids or their
corresponding cyclic dimers are present at a molar fraction less
than about 0.25, more preferably less than about 0.15, and most
preferably less than about 0.05.
[0094] Multiple ester linked units A, B and C are covalently
connected via ester groups to produce the crosslinked aliphatic
polyester compositions. Ester linked units A, B and C may be
arranged via a multiplicity of covalent ester connections in any
possible chain microstructural sequence. An ester linked unit A may
be covalently connected to: a) another ester linked unit A, b) an
ester linked unit B, or c) an ester linked unit C. Likewise, an
ester linked unit B may be covalently connected to a) an ester
linked unit A, or b) another ester linked unit B, or c) an ester
linked unit C. An ester linked unit C may be covalently connected
to a) an ester linked unit A, or b) an ester linked unit B.
[0095] Phase separated crosslinked polyester compositions may have
a macroscopic topology or structural morphology with submicron to
micron sized spatially distinct regions. For example, there may be
chains rich in ester linked unit A dispersed within, or
co-continuous with, regions having chains rich in ester linked unit
B. Alternatively, this macroscopic topology or structural
morphology also may be manifested by submicron to micron sized
spatially distinct regions having chains rich in ester linked unit
B dispersed within, or co-continuous with, regions having chains
rich in ester linked unit A.
[0096] Unreacted primary and secondary hydroxyl groups and
carboxylic acid groups may be present within the crosslinked
polyester compositions. These unreacted groups provide a means by
which the crosslinked polyester compositions may be chemically
modified. Chemical modification may be affected by reaction with
any compound capable of reacting with primary hydroxyl, secondary
hydroxyl or carboxylic acid groups.
[0097] The compositions described above may be produced under
typical conditions for polycondensation reactions of polyols and
diacids. The polycondensation reaction may be catalyzed or not. If
catalyst(s) is used, preferably it is biocompatible, and more
preferably it is bioabsorbable. The particular process conditions
chosen will depend on numerous factors including, but not limited
to, the desired properties of the final product, the viscosity of
the reaction mixture and the melting temperature of the polymer or
monomer reactants.
[0098] Degree of conversion is a measure of the extent of monomeric
reaction in the reaction mixture. The degree of conversion can be
quantified by various techniques known in the art. For example, the
reaction may be monitored by measuring the amount of byproduct
water evolved. Alternatively, titration of residual carboxylic acid
may be used to monitor the reaction.
[0099] To increase degree of conversion, the reactions may be
conducted at elevated temperatures and/or under inert gas blanket
(e.g., nitrogen gas). Continuous removal of byproduct(s) also may
increase degree of conversion; vacuum or nitrogen blanket are
useful in this regard. The reactions generally are conducted above
120.degree. C. Increasing the reaction temperature will reduce the
reaction times required to attain a particular degree of
conversion.
[0100] The crosslinked polyester compositions may be produced by
different polycondensation processes. Monomeric triol, diol and
diacid may be combined at elevated temperature(s) such that the
monomer mixture is reacted. In a one stage process, the reaction is
driven directly to the desired degree of conversion beyond a gel
point. This may be preferable if the material is to be used for
molding, combination or in circumstances where other isolation unit
operation is not desired.
[0101] In a two stage process, the first step is the
above-described initial reaction, which is stopped at a degree of
conversion below the gel point to yield an intermediate reaction
product. The intermediate reaction product may be a waxy solid at
room temperature and may be used to mold polymer solids, or may be
combined with porogen to produce polymer foams, or may be
macroscopically combined with other materials to produce composite
structures, or may be combined with diisocyanates to produce
urethane linked foams as described below. In the second stage of
this method, the polymerization reaction is driven beyond the gel
point to yield a crosslinked polymeric product.
[0102] Preferably, the second stage polymerization reaction is
continued until the unreacted carboxylic acid is present at a
concentration less than about 1.0 meq. acid/gram, more preferably
less than 0.5 meq. acid/gram to yield the crosslinked polymer
compositions, and most preferably less than 0.3 meq. acid/gram.
[0103] Alternatively, the crosslinked polymer compositions may be
produced so that the chain microstructural sequence or "order" of
the units is non-random. In this process, uncrosslinked polymer
intermediates are first made. Then, these intermediates are melt
mixed in appropriate proportions and subsequently driven beyond the
gel point to yield crosslinked polymeric compositions.
[0104] For example, in this process a first polymer may be made
from a diacid and a diol, and a second polymer made from a diacid
and a triol. Most generally, these initial polymer reactions are
stopped before the degree of conversion is beyond the gel point.
Then the two polymers are mixed together under conditions favorable
to further polymerization such that the intermediate polymers
become crosslinked to one another. It should be appreciated that
these intermediate polymers may or may not be homopolymers.
[0105] Porous articles or foams may be formed of the crosslinked
polymer compositions such as depicted in FIG. 1. This porous foam
(1) has a structure that includes voids or pores (2). These may be
called cells. In FIG. 1, the cells are depicted as closed cells,
cell walls, or surfaces of the bubbles, are not broken. It should
be understood that the foamed or sponge-like porous materials may
be of closed cell, open cell or hybrid cell type. The walls of
these cells comprise crosslinked polymer compositions (3). Porous
articles of the crosslinked polymer compositions may exhibit shape
memory behavior or not.
[0106] Porous articles may be prepared by methods and techniques
known in the art, such as solvent casting, entraining air, porogen
removal, CO.sub.2 foaming and like processes.
[0107] An illustrative porogen removal process for producing porous
articles also will now be described. A porogen may be a solid,
liquid, or gaseous material that is removable from the polymer
composition to create pores or voids, thereby lowering the
effective density of the resulting material. Exemplary porogens
include, but are not limited to, collagen, gelatin, inorganic salt
(e.g., potassium chloride, sodium chloride, sodium citrate, sodium
tartrate), paraffin, saccharose and combinations thereof. The size
and shape of the porogen particles will affect the size and shape
of the resulting pores, and the polymer to porogen ratio is
correlated to the amount of porosity of the final structure.
[0108] Preferably, when porous articles are prepared by porogen
removal, the porogen is selected so that it can be removed by using
a non-cytotoxic solvent (e.g., water). Alternatively, the porogen
may be selected so that the solvent, although potentially
cytotoxic, does not remain in the porous article after appropriate
processing.
[0109] For example, sodium chloride may be used as a porogen to
create pores that correspond to the individual salt crystals. In a
salt-bed process, an intermediate reaction product is distributed
through a bed of salt crystals. The intermediate product may be
further polymerized. The salt crystals may be removed by rinsing,
for example, with deionized water. The salt crystals or other
porogen may be removed by an appropriate process before the polymer
is fully crosslinked, or after crosslinking.
[0110] The porous articles may include urethane linked foams.
Urethane linked foams may be prepared from the uncrosslinked
intermediate reaction products described above. For example,
diisocyanate may be added to molten intermediate. Such
diisocyanates react to form urethane and urea linkages. Exemplary
urethane and urea linkages are:
##STR00004##
[0111] where R.sub.5, R.sub.6, and R.sub.7, are each independently
a divalent aromatic or aliphatic moiety. An exemplary diisocyanate
is 4,4'-methylenebis(phenyl isocyanate).
[0112] The final foam density is a function of the weight fraction
of diisocyanate added to the intermediate. Preferably, the urethane
and urea linkages comprise about 15 mole % of less of the polymer
composition.
[0113] These foams may be semicrystalline or amorphous at room
temperature. Such foams may exhibit shape memory behavior or not,
and may be nontoxic to mammalian cells.
[0114] The crosslinked polymer compositions are advantageously
macroscopically combined with other materials to construct
composites, such as fibrous composites, laminates, and particulate
composites. The other materials may be continuously or
discontinuously distributed within the crosslinked polymer
compositions. Alternatively, the crosslinked polymer compositions
may be continuously or discontinuously distributed within the other
materials.
[0115] Numerous fabrication methods and techniques are known in the
art for manufacturing composites. For example, the crosslinked
polymer compositions can be coated on, laminated to, or imbibed
within these other materials to form a composite. Preferably, the
crosslinked polymer compositions contact the other materials. These
other materials can have various forms and shapes. Illustrative
forms include fibers, particles, rods, sheets and tubes.
[0116] These composites may incorporate various other materials,
such as film materials, fibrous materials and porous membrane
materials. Preferably, these other materials are a fluoropolymer,
more preferably, polytetrafluoro-ethylene, and most preferably
expanded polytetrafluoroethylene. Alternatively, these other
materials preferably are bioabsorbable, more preferably are
poly(glycolide-co-trimethylene-carbonate) (PGA/TMC).
[0117] The composites and/or the other materials may exhibit shape
memory behavior or not. The composites and/or the other materials
may be biocompatible or not. The composites and/or the other
materials may be degradable via hydrolysis or not. Preferably, the
composites and other materials are biocompatible and/or
bioabsorbable. Preferably, the crosslinked polymer compositions
impart shape memory properties to the final composites.
[0118] Referring to FIG. 2-6, various composites are constructed in
accordance with the present application as shown. FIG. 2 shows an
imbibed ePTFE composite. The ePTFE material has a microstructure of
interconnected fibrils that defines micropores. The microstructure
includes nodes (4) and fibrils (6). A crosslinked polymer
composition (3), such as described herein, has been imbibed into
the microstructure. Preferably, the crosslinked polymer composition
(3) is securely adhered to both the external and internal surfaces,
i.e., the fibrils and/or nodes of the ePTFE material. The imbibing
may be partial or full. When full or complete imbibing has been
accomplished, the structure of the imbibed ePTFE composite may
consist essentially of PTFE and crosslinked polymer compositions
described herein.
[0119] In FIG. 3, an ePTFE material portion (8) is joined with a
crosslinked polymer composition portion (3). In FIG. 4, an ePTFE
material portion (8) is between two crosslinked polymer composition
portions (3). Between the ePTFE material portion (8) and the
crosslinked polymer composition portion (3) is defined an interface
(10). It also is possible to imbibe ePTFE (8) with a polymer
composition (3) that is subsequently crosslinked, and also to join
that imbibed ePTFE to a second crosslinked polymer composition
portion (3) as shown in FIG. 5. The two crosslinked polymer
compositions may be the same or different. In FIG. 6, porous foam
(1) with cells (2) is made of a crosslinked polymer composition (3)
as described herein and is joined to another material (8).
[0120] For some applications, it may be desirable to provide an
adhesive or compatibilizing compound (12) at the interface as shown
in FIG. 3.
[0121] Fibrous composites may be formed by combining the
crosslinked polymer compositions with fibrous materials. The
fibrous materials may be discontinuous (randomly arranged or not).
Alternatively the fibrous materials may be continuous filaments,
woven or non-woven materials, braided materials or 3-D preforms.
Such fibrous composites may include multilayer composites. Said
fibrous materials are combined with the crosslinked polymer
compositions in any weight fraction or volume fraction that is
reasonable for the intended use. Preferably, the volume fraction
fibrous material, .phi..sub.fibrous is in the range
0.01.ltoreq..phi..sub.fibrous.ltoreq.0.7.
[0122] Preferred ceramic and inorganic materials include, but are
not limited to, alumina, alumina silicate, bismuth titanate, boron
nitride, calcium phosphate, carbon, carbon nanotubes, glass,
graphite, hydroxyapatite, lead metaniobate, lead nickel niobate,
lead zirconate titanate, lithium aluminate, oxide nanotubes,
silicon carbide, silicone nitride, tin oxide, titanium dioxide,
yttrium aluminum garnet, zirconium diboride, and combinations
thereof.
[0123] Said fibrous materials may be ceramic, inorganic, metallic
or polymeric. Preferred metallic fibrous materials include, but are
not limited to, aluminum, copper, gold, iron, magnesium,
nickel-titanium, platinum, silver, steel, alloys thereof, and
combinations thereof. Preferred polymeric fibrous materials
include, but are not limited to, cellulose, cellulosic derivatives
(e.g., carboxymethylcellulose and hydroxyethylcellulose), chitin,
chitosan, collagen, fluoropolymers, polyacrylates, polyamides,
polyanhydrides, polyesteramides, polyesters, polyesterurethanes,
polyetheramides, polyetheresters, polyetheresterurethanes,
polymethacrylates, polyolefins, polyurethanes, polyvinylalcohol,
and combinations thereof. More preferred polymeric fibrous
materials include aliphatic polyamides, aliphatic polyesters,
carboxymethylcellulose, cellulose, chitin, chitosan, collagen,
poly(ethylene terephthalate), poly(ethylene-co-propylene),
poly(fluorinated ethylene-co-propylene),
poly(tetrafluoroethylene-co-ethylene),
poly(tetrafluoroethylene-co-hexafluoropropylene),
poly(tetrafluoroethylene-co-perfluorobutyl vinyl ether),
poly(tetrafluoroethylene-co-perfluoroethyl vinyl ether),
poly(tetrafluoroethylene-co-perfluoromethyl vinyl ether),
poly(tetrafluoroethylene-co-perfluoropropyl vinyl ether),
polyetheramides, polyetheresters, polyethylene, polypropylene,
polytetrafluoroethylene, polyvinylalcohol, and combinations
thereof. Most preferred polymeric fibrous materials include
aliphatic polyamides, aliphatic polyesters (e.g., bioabsorbable
aliphatic polyesters prepared by a ring opening polymerization
method such as poly(glycolide-co-trimethylene carbonate),
poly(L-lactide), poly(D-lactide), poly(D,L-lactide),
poly(glycolide-co-lactide) and poly(.epsilon.-caprolactone)),
carboxymethylcellulose, cellulose, chitin, chitosan, collagen,
polyetheramides, polyetheresters, polytetrafluoroethylene (e.g.,
expanded polytetrafluoroethylene), polyvinylalcohol. Fibrous webs
of the bioabsorbable fibers can be produced by melt-blowing or
spun-bonding. Meltblown fibrous webs are produced by entraining
melt spun fibers with convergent streams of heated air to produce
fine filaments.
[0124] Preferably, the other material is a self-cohering non-woven
web constructed from continuous filaments of semicrystalline
multicomponent polymeric systems. The self-cohering webs of U.S.
Pat. No. 6,309,423 are particularly preferred.
[0125] Film-based composites may be made from the crosslinked
polymer compositions themselves, or in combination with other film
materials, including multilayer film laminates. Said film materials
may be of the fully-dense type or of the porous type. Said film
materials may be ceramic, inorganic, metallic or polymeric.
Metallic film materials and polymeric film materials are
preferred.
[0126] Preferred metallic film materials include aluminum, copper,
gold, iron, magnesium, nickel-titanium, platinum, silver, steel,
alloys thereof and combinations thereof.
[0127] Preferred polymeric film materials include fluoropolymers,
polyacrylates, polyamides, polyanhydrides, polyesteramides,
polyesters, polyesterurethanes, polyetheramides, polymethacrylates,
polyolefins, polysiloxanes, polyurethanes, polyvinylalcohol, and
combinations thereof. More preferred polymeric film materials
include aliphatic polyamides, aliphatic polyesters, poly(ethylene
terephthalate), poly(ethylene-co-propylene), poly(fluorinated
ethylene-co-propylene), poly(tetrafluoroethylene-co-ethylene),
poly(tetrafluoroethylene-co-hexafluoropropylene),
poly(tetrafluoroethylene-co-perfluorobutyl vinyl ether),
poly(tetrafluoroethylene-co-perfluoroethyl vinyl ether),
poly(tetrafluoroethylene-co-perfluoromethyl vinyl ether),
poly(tetrafluoroethylene-co-perfluoropropyl vinyl ether),
polyetheramide, polyethylene, polypropylene, polysiloxanes,
polytetrafluoroethylene, polyurethanes, and polyvinylalcohol. Most
preferred polymeric film materials include aliphatic polyamides,
aliphatic polyesters (e.g., bioabsorbable aliphatic polyesters
prepared by a ring opening polymerization method such as
poly(D,L-lactide), poly(D-lactide), poly(glycolide-co-lactide) and
poly(.epsilon.-caprolactone),
poly(glycolide-co-trimethylenecarbonate), and poly(L-lactide)),
polyetheramides, polytetrafluoroethylene (e.g., expanded
polytetrafluoroethylene), and polyvinylalcohol.
[0128] Said film materials are combined with the crosslinked
polymer compositions in any weight fraction or volume fraction that
is reasonable for the intended use. Preferably, the volume fraction
film material, .phi..sub.film is in the range
0.01.ltoreq..phi..sub.film.ltoreq.0.95.
[0129] Said film laminates may comprise one or more layers of the
crosslinked polymer compositions and, optionally, one or more
layers of film material. For example, a laminate may be made from
an ePTFE layer and one or more crosslinked polyester compositions.
The ePTFE has a microstructure of interconnected fibrils that
defines pores. Preferably, the crosslinked polyester compositions
has at least one transition temperature of greater than about
30.degree. C. and less than about 100.degree. C. and is laminated
to the ePTFE layer. Preferably, at least some of the crosslinked
polyester composition flows into at least some of the pores to
provide attachment. Alternatively, the crosslinked polyester
composition and the ePTFE may be attached via surface adhesion.
[0130] In alternative embodiments, ePTFE material may be combined
with other shape memory polymer materials in accordance with the
methods disclosed herein. These shape memory polymer materials
include, but are not limited to the crosslinked polyester
compositions described in the present application.
[0131] For example, a multi-layer film laminate may be made from
three different crosslinked polyester compositions described in the
present application. By choosing appropriate compositions with
different transition temperatures, it is possible to provide a
multi-layer film laminate that exhibits staged shape memory
behavior. For example, it is possible to form a compressed laminate
that may be inserted into a patient in the compressed state. Then
by appropriately stimulating the laminate (e.g., heating to
37.degree. C.), the laminate may expand in a predetermined
direction by a predetermined amount. In some patients, this degree
of expansion may be appropriate, and in others additional expansion
may be desirable. In the latter group of patients, the laminate may
be again stimulated to invoke a shape memory reaction in one or
more of the remaining layers. For example, this might be achieved
by heating the laminate to 45.degree. C., and to cause additional
expansion of the laminate material. By incorporating additional
layers of the crosslinked polymer compositions on the film
laminates, it is possible to produce a composite material which
exhibits two, three, four or more stages of controlled shape memory
behavior. Alternatively, the composite may be stimulated to move in
a first direction by a first trigger and then stimulated to move in
a second direction (e.g., opposite the first direction) by a second
trigger.
[0132] Said crosslinked polymer compositions may function to bond
film materials to one another to form a multilayer film laminate
article comprising the crosslinked polymer compositions.
[0133] Alternatively, the other materials in the composite are
microporous membranes include, but are not limited to, cellulosics,
chlorinated polymers, fluorinated polymers,
poly(tetrafluoroethylene-co-ethylene),
poly(tetrafluoroethylene-co-hexafluoropropylene),
poly(tetrafluoroethylene-co-perfluorobutyl vinyl ether),
poly(tetrafluoroethylene-co-perfluoroethyl vinyl ether),
poly(tetrafluoroethylene-co-perfluoromethyl vinyl ether),
poly(tetrafluoroethylene-co-perfluoropropyl vinyl ether),
polyamides, polycarbonates, polyolefins and combinations thereof. A
most preferred material is expanded porous polytetrafluoroethylene
(PTFE) made in accordance with the teachings of U.S. Pat. No.
3,593,566 herein incorporated by reference. This material is
commercially available in a variety of forms from W. L. Gore &
Associates, Inc., of Elkton, Md. Such membranes preferably have a
thickness from about 5 .mu.m to up to 1.0 mm, a porosity of greater
than 10%, and a pore diameter less than 10 microns.
[0134] Where an expanded PTFE membrane is used, the preferred
thickness is at most about 1.0 mm and most preferably between 5
.mu.m and 0.019 mm, the preferred porosity is between 20-98% and
most preferably is between 70-95%, and the preferred pore diameter
is between 0.05 .mu.m and 5 .mu.m, and most preferably is about 0.2
.mu.m.
[0135] Other composites are formed by combining the crosslinked
polymer compositions with particulates (e.g., a filled polymer).
Such particulates may be chosen to improve acoustic, dimensional
stability, electrical, frictional wear, lubrication, magnetic,
processability, strength, toughness properties. The particulates
may be in various forms, including, but not limited to, aggregates,
blocks, cubes, fibers, flakes, spheres, tubes and combinations
thereof. Particulate materials include, but are not limited to,
beidellite, bentonite, biodegradable polymeric particles (e.g.,
polydioxanone, polyglycolic acid, polyglycolide, polylactic acid,
polylactide, and copolymers of glycolic acid or glycolide and
either lactic acid, lactide or trimethylene carbonate), calcite,
carbon, carbon black, ceramics (e.g., alumina and layered aluminate
oxides), glass (e.g., spheres or fibers), hectorite, hydrotalcite,
illite, kaolinite, mica, montmorillonite, nontronite, saponite,
sauconite, sepiolite, stevensite, talc, vermiculite and
combinations thereof. Preferably, the particulates are
biocompatible particulates, and more preferably are bioabsorbable.
Such particulate based composites may be useful for nano-composite
materials.
[0136] Optionally, the composite membrane may be reinforced with a
woven or non-woven material joined to the other material. Suitable
woven materials include for example, scrims made of woven fibers of
expanded porous polytetrafluoroethylene, commercially available
from W. L. Gore & Associates, Inc., of Elkton, Md.; webs made
of extruded or oriented polypropylene netting commercially
available from Conwed, Inc. of Minneapolis, Minn.; and woven
materials of polypropylene and polyester of Tetko Inc., of
Briarcliff Manor, N.Y. Suitable non-woven materials include for
example, a spun-bonded polypropylene or polyester.
[0137] For example, a polypropylene woven fabric may be laminated
to the other material by any conventional technique, including, but
not limited to, hot roll lamination, ultrasonic lamination,
adhesive lamination, forced hot air lamination and other techniques
so long as the technique does not damage the integrity of the other
material. Preferably, such lamination is achieved before the other
materials are combined with the crosslinked polymer compositions.
The support structure may aid in processing and/or provide improved
mechanical properties to the final composite.
[0138] The composites may be formed by imbibing within the voids or
pores of the other materials an intermediate polymer composition
obtained from a first polymerization stage of the two-stage
manufacturing process described above. Preferably, the intermediate
polymer composition substantially imbibes into the other materials
to fill the voids or pores. Alternatively, only some of the voids
may be filled or all of the voids may be partially filled. In
another alternative, the other material may be coated with
crosslinked polymer compositions, or the crosslinked polymer
compositions can be cast as a sheet, and laminated to another
material. In yet another alternative, the hydroxyl or carboxylic
acid groups of the crosslinked polyester may be conjugated with
moieties of the other materials. Combinations of these embodiments
are possible.
[0139] In one embodiment, the intermediate polymer is dissolved in
a solvent to form an intermediate solution before imbibing. The
resulting intermediate solution is applied to the other material so
as to imbibe and occlude the voids or pores of the other material.
Solvents that may be suitable for use include, but are not limited
to, acetone and methyl ethyl ketone.
[0140] The solution may be applied to the membrane by any
conventional coating technique including, but not limited to,
forward roll coating, reverse roll coating, gravure coating, doctor
coating, kiss coating, dipping, brushing, painting, and spraying so
long as the liquid solution is able to penetrate the voids of the
other material. Excess solution from the surface of the other
material may be removed. After treatment, the other material is
dried either at room temperature or at an elevated temperature.
Oven temperatures may range from 60-200.degree. C., preferably
120-160.degree. C. Preferably, this treatment step is repeated
until voids of the other material are completely filled.
[0141] The actual number of treatments necessary to achieve a
predetermined degree of filling is dependent on the thickness and
porosity of the other material. Preferably, the solution is applied
to the other material with between 1 and 8 treatments. Optionally,
both sides of the other material may be treated simultaneously
thereby reducing the number of treatments required.
[0142] Alternatively, hot melt processes may be used to flow the
intermediate polymer at least partially into the pores of the other
materials. For example, an intermediate reaction product (discussed
above) is formed from a diol, a triol and a diacid, and that
intermediate reaction product is heated, preferably to a
temperature at which the melt viscosity is greater than about 0.01
poise and less than about 1,000 poise, combined with a porous
substrate material such that the intermediate reaction product is
disposed within at least some of the pores of the substrate, and
then the resulting composite is cooled. Melt viscosity may be
determined by standard techniques, such as parallel plate or cone
and plate techniques.
[0143] Regardless of the method of imbibing and once the pores of
the other materials are filled sufficiently with the intermediate
polymer, polymerization preferably is continued to achieve a
desired residual acidity. Preferably, the residual acidity is in
the range of greater than about 0.0001 meq. acid/gram to less than
about 1.0 meq. acid/gram. The composite material preferably is
heated under vacuum or inert gas during such polymerization. It
also is possible to react the inventive reaction compositions with
the other materials.
[0144] Medical devices disclosed herein may comprise either the
crosslinked polymer compositions described herein (having shape
memory or not) or other shape memory materials. The crosslinked
polymeric materials may be used in combination with other materials
(including, but not limited to other polymeric, metallic, inorganic
and ceramic materials) to form composites useful in medical
devices. These materials or composites may be porous materials or
foams or not.
[0145] Medical devices may incorporate a polyester composition that
does not have shape memory properties. For example, the polymer
compositions described herein may be used in hemostatic plugs as
described below.
[0146] Alternatively, the medical devices described herein may
utilize shape memory behavior. In this aspect, such medical devices
have at least one component having an undeployed shape and a
deployed shape, corresponding to a metastable state and a original
or stored state of the shape memory polymer, respectively. Such
medical devices may utilize the transition from the metastable
state to the original state. Stimulation of the shape memory
property causes deployment of the component by initiating a
transition in the shape memory material from the metastable state
to the original state. The transition may be stimulated by any
stimulus, such as the stimuli described above including, but not
limited to, light, heat, radiation or other.
[0147] Where the stimulus is heat, the shape memory component is
deployed by heating to a temperature and for a time sufficient to
melt a crystalline or semi-crystalline phase of the shape memory
material.
[0148] Medical devices utilizing heat as a stimulus are prepared by
heating the shape memory component (in its deployed shape) to a
temperature and for a time sufficient to melt a crystalline or
semi-crystalline phase of the shape memory material. While heated,
the shape memory component is deformed from the deployed shape to
an undeployed shape. The component then is cooled. During this
cooling, a crystalline or semi-crystalline phase of the shape
memory material forms. Preferably, this cooling is to room
temperature. Because the crystalline or semi-crystalline phase is
formed, the shape memory component is fixed in the undeployed
shape. It is intended that the shape memory component will retain
this undeployed shape at room temperature indefinitely (metastable
state), and will be capable of reverting to the original or
deployed shape upon application heating to a temperature and for a
time sufficient to melt a crystalline or semicrystalline phase of
the shape memory material.
[0149] One such exemplary medical device is an aneurysm repair
device (20) that is shown in FIGS. 7-9. Such devices may be used to
deliver a shape memory component in a compressed undeployed shape,
and then selectively deployed once it has been placed within the
aneurysmal sac to fill the aneurysmal sac.
[0150] Aneurysm repair device (20) has a shape memory component
(22), which can be made using any of the materials discussed
herein. Advantageously, the shape memory component (22) is foam
(22). In an alternative embodiment, the aneurysm repair device (20)
has a foam component (22) that does not exhibit shape memory
behavior, but rather mechanically expands.
[0151] Preferably, the compression reduces at least one dimension
of the foam by at least 50%, more preferably by at least 70% and
most preferably by at least 75% of the like dimension of the
deployed shape. The foam then is cooled to room temperature. This
provides a metastable compressed foam.
[0152] The compressed foam then is releasably affixed to an
actuator, which is configured to selectively stimulate the foam to
change from the metastable state to the original state thereby
deploying the device. In FIG. 7, this actuator is based on
resistive heating. An electrically conductive wire (26) is at least
partially covered with insulation (28).
[0153] The insulated wire (26, 28) then is disposed within a shield
conductor (32), which in turn is disposed within an insulation
cover (30). At the distal end, closest to the foam (22), the
actuator is provided with a resistive element (34). Preferably,
each of the elements of the actuator is biocompatible.
[0154] It should be understood that, alternative means for
stimulating the metastable compressed foam (22) are possible. For
example, instead of resistive heating, an optical fiber may be used
and laser light may be directed on the metastable compressed foam
(22) to stimulate its shape memory behavior. In such an embodiment,
it may be advantageous to include a dye in the metastable
compressed foam (22) to facilitate shape memory behavior.
[0155] In use, the aneurysm repair device (20) is delivered
endovasularly to the site of the aneurysm. It then is positioned
within the aneurysm. Once the shape memory material (22) is
properly placed, electrical power is applied to the electrically
conductive wire (26). This, in turn, causes heating of the
resistive element (34). The shape memory material (22) is heated
above its transition temperature by the resistive element (34), and
the shape memory material (22) exhibits shape memory behavior, and
expands to its original state (24) as shown in FIG. 9. In so doing,
it is intended that the expanded shape memory material (24) will
fill and occlude the aneurysmal sac. Thereafter, the actuator is
removed from the expanded shape memory material (24) and is
withdrawn from the patient.
[0156] Another exemplary medical device is an intraluminal delivery
device (40) that is shown in FIGS. 10-14. Such an intraluminal
delivery device (40) is intended to permit repair of openings in a
lumen, particularly in the vasculature (e.g., femoral artery). Such
openings are frequently formed to permit introduction of medical
device(s) for medical procedures, e.g., endovascular procedures to
treat aneurysms, cerebral vascular malformations, and arteries that
have been occluded by plaque. For example, shape memory foam may be
used to repair a vascular access wound that results from the
introduction and removal of a device used in a minimally invasive
surgical procedure. The foams may be manipulated, formed and
delivered in such a way to act as vascular closure devices that
take advantage of the hemostatic properties shown in the examples
below.
[0157] Broadly speaking, such a device includes an introducer (44),
and a vascular closure assembly (45). Introducers are well known in
the art. In the embodiment depicted in FIGS. 10-13, the introducer
(44) is a sheath defining a central lumen.
[0158] A vascular closure assembly (45) (depicted in FIG. 13) is
within the introducer (44), and has a distal end (46) and a
proximal end (48). In the embodiment depicted in FIGS. 10-14, the
vascular closure assembly (45) has a shaft member (50), a shape
memory member (52) and a pusher (54). The introducer (44), the
shaft member (50), the shape memory member (52) and the pusher (54)
are movable independently with respect to one another.
[0159] The shaft member (50) extends between the distal and
proximal ends, and has an expandable portion (56) capable of being
selectively deformed between a retracted position and an expanded
position. The expandable portion (56) is near the distal end
(46).
[0160] The shaft member (50) may, for example, be made from braided
nitinol wire. A non-expandable portion (58) of the shaft member
(50) may be made by substantially covering the braided shaft with a
polymeric material, which prevents radial expansion, elongation or
shortening of the braid in that portion. Alternatively, expansion
of the braided shaft also may be restricted by applying the
polymeric material along a portion of the inner lumen of the
braided shaft. Likewise, materials other than polymeric materials
may be used for this purpose.
[0161] An actuating wire (60) is disposed within the shaft member
(50) and is attached to the distal end (46).
[0162] It should be understood that the shaft member may be made
from various other biocompatible materials (e.g., stainless steel),
so long as the material is capable of being selectively deformed
between the retracted and expanded positions. Likewise, the shaft
member may be constructed without braiding using other
manufacturing techniques including, but not limited to, adhering
(e.g., biocompatible adhesives), fusion welding, laser cutting,
laser welding, soldering, and combinations thereof.
[0163] The shape memory member (52) of the vascular closure
assembly (45) may be made of any of the materials discussed above
so long as it exhibits shape memory behavior. Preferably, the shape
memory member (52) is bioabsorbable. In the embodiment depicted in
FIGS. 10-14, the shape member is compressed shape memory foam plug
(52) disposed around the shaft member (50).
[0164] The pusher (54) also is disposed within the introducer (44)
and is proximal to the foam plug (52). In the embodiment depicted
in FIGS. 10-14, the pusher (14) surrounds a proximal portion of the
shaft member (50).
[0165] The intraluminal delivery device may be used as follows.
First, the introducer (44) is inserted into a lumen (42).
Typically, a needle (not depicted) is first inserted into a lumen
(42). Then, a guide wire (not depicted) is placed through the
needle into the lumen. The needle then is removed. An introducer
(44) is placed over the guide wire and into the lumen (42).
[0166] Insertion of the introducer (44) creates an opening in the
lumen (42). Various medical device(s) (not depicted) may be
delivered into the patient via the introducer (44). Once the
medical procedures are completed, the vascular closure assembly
(45) is delivered to the repair site via the introducer (44) and
preferably over the pre-existing guide wire (not depicted).
[0167] The expandable portion (56) of the shaft member (50) is
positioned beyond the repair site. Then the expandable portion (56)
is expanded by holding the proximal end (48) of the vascular
closure assembly (45), and pulling the actuating wire (60)
proximally. This causes the distal end (46) of the vascular closure
assembly (45) to move proximally, and the expandable portion (56)
to expand within the unrestrained portion to form a projection (62)
extending perpendicularly to a longitudinal axis of the device as
shown in FIG. 11.
[0168] Next, the pusher (54) and the plug (52) are pushed distally
against the projection (62). With the plug (52) locked between the
pusher (54) and the projection (62), the vascular closure assembly
(45) is withdrawn proximally until the projection (62) contacts an
inner surface of the lumen (42) as shown in FIG. 12.
[0169] The shape memory property of the plug (52) is activated
either by body heat or a stimulus (e.g., via warm saline solution
provided through the introducer). The stimulus causes the
deployment of the plug (i.e., invokes transition from the
metastable state to its original state). The introducer (44) then
is withdrawn. See FIGS. 12-13. The unrestricted plug (52) then
expands to patch the opening of the lumen (42) as can be seen in
FIGS. 13 and 14. The plug (52) is disposed against an outer surface
of the lumen (42). In some embodiments, a portion of the polymeric
foam also may be disposed within a hole (64) created by the
introducer (44) as shown in FIG. 14; however this may not be
necessary for an effective repair.
[0170] After placing the plug (52), the expandable portion (56) is
retracted by pushing the actuating wire (60) distally. The shaft
member (50) may be withdrawn while the plug (52) is held in place
by the pusher (54), which is ultimately removed.
[0171] Another exemplary medical device is a deployment means (80)
for an endoluminal device, e.g., a stent that is shown in FIGS.
15-16. Other illustrative endoluminal devices include, but are not
limited to, endoluminal prostheses, stent-grafts, vena-cava
filters, and the like. The stent (82) may or may not be made of a
shape memory alloy.
[0172] A shape memory material or a shape memory prepolymer (84) is
applied to the braided stent (82). The shape memory material (84)
may be any of the materials discussed herein so long as it exhibits
shape memory behavior. For example, the shape memory material (84)
may be a composite material, e.g., a composite material including a
crosslinked polymer composition exhibiting shape memory behavior,
as well as another material. In one preferred embodiment, the shape
memory material (84) is bioabsorbable. In another preferred
embodiment, the shape memory material (84) is a composite including
a crosslinked polymer composition and an ePTFE nonwoven web.
[0173] An exemplary method of manufacturing a deployment means is
now described. First, the stent (82) is formed. As shown in the
depicted embodiment, a nitinol wire is braided into a generally
tubular construct on a mandrel. Alternatively, the stent may be
constructed using other known materials and techniques including,
but not limited to adhering (e.g., biocompatible adhesives), fusion
welding, laser cutting, laser welding, soldering. A further
alternative is to manufacture the stent from a sheet or cannula,
e.g., using a laser.
[0174] The second step is to apply the shape memory material (84)
to the stent (82). For example, the shape memory material (84) may
be continuously wrapped in a machine direction around an exterior
surface of the braided stent (82). The assembly then is heated to
relatively high temperatures (e.g., 160.degree. C.) for an extended
period (e.g., 10 hours). After cooling to room temperature, the
assembly including the stent (82) and the applied shape memory
material (84) may be removed from the mandrel. The deployment means
is in an expanded or deployed shape (1) as shown in FIG. 15. This
corresponds to the original state of the shape memory
composite.
[0175] The third step is to change the profile of the deployment
means. The deployment means (80) is heated to a temperature and for
a time period sufficient to melt a crystalline or semi-crystalline
phase of the shape memory material and axially stretched, for
example by grabbing and pulling the two opposing ends of the
nitinol braid (82). This axial stretching causes the diameter of
the deployment means to be reduced and the overall length of the
deployment means to be increased. The deployment means is in an
undeployed shape in FIG. 16. The deployment means (90) then is
cooled. After being fixed in an undeployed shape (metastable
state), the deployment means is placed on a delivery catheter.
[0176] A deployment means may be used as follows. Typically, a
needle is first inserted into a blood vessel. Then, a guide wire is
placed through the needle into the blood vessel. The needle then is
removed. An introducer is placed over the guide wire and into the
blood vessel. Next, the delivery catheter with the deployment means
is advanced through the introducer over a guide wire and into the
blood vessel. The catheter then is guided to the desired location
within the vasculature (e.g., aorta) and the guide wire is
removed.
[0177] The deployment means then is stimulated to cause the
deployment means to revert to its deployed shape, i.e., the
deployment means shortens in length and expands in diameter, and
preferably substantially recovers its original dimensions. For
example, the deployment means is heated to a predetermined
temperature, i.e., a transition temperature of the shape memory
material (84). This heating may be accomplished by the patient's
own body heat, warm saline provided via the introducer, etc.
[0178] The aliphatic crosslinked polyester and composites made
therefrom are extremely well-suited for various applications,
particularly those benefiting from biocompatibility,
bioabsorbability, shape memory behavior or combinations thereof.
Illustrative examples of medical applications include, but are not
limited to bandages, bone pins, drug delivery devices, grafts,
hemostatic devices, stents, surgical reinforcement, sutures,
vascular closure devices, and the like. Non-medical applications
include, but are not limited to packaging and food preparation and
other uses where disposability is of concern.
[0179] The following examples are intended to demonstrate, but not
to limit, the invention(s) described herein, and methods of making
them.
Example 1
[0180] A crosslinked polymerization reaction product of a diacid,
diol and a triol was made following a two stage method. In the
first stage, the following components were placed into a 500 ml
glass reactor: The diacid component was 202.25 grams sebacic acid
(Aldrich, 99%), the diol was 43.46 grams ethylene glycol (Aldrich,
99.8% anhydrous), and the triol was glycerol in the amount of 26.26
grams (Aldrich, 99.5%+spectrophotometric grade). The reactor was
equipped with agitation, heating, vapor condensing, liquid volume
measuring, temperature regulating, temperature measuring and
nitrogen gas purging capabilities.
[0181] At room temperature the reactants formed a heterogeneous
mixture of solid and liquid phase. As temperature was increased to
about 170.degree. C., the mixture became a homogeneous liquid. Time
and process parameters were recorded when all material was a single
phase liquid. Byproduct water vapor evolving from the reactor was
condensed and collected in a volumetric receiving tube graduated in
0.1 cc increments. The temperature and water evolution history is
shown in FIG. 17. A total of 32.2 cc byproduct water was
collected.
[0182] 237 grams of white waxy intermediate reaction product,
corresponding to 98.9% of the theoretical yield, was produced in
the first stage of polymerization. The product was titrated with
potassium hydroxide (KOH). Titration reflected a residual acidity
of 0.8049 meq. acid/gram. The product was soluble in acetone at
room temperature.
[0183] In the second stage, 9.05 grams of the intermediate reaction
product (prepared as described above) was placed into each of four
125 mm diameter Teflon.TM. molds at 22.degree. C. The Teflon.TM.
molds containing the intermediate were placed in a vacuum oven with
the temperature set at 130.degree. C. The pressure was initially
set at atmospheric pressure. The intermediate reaction product
melted to form a clear viscous liquid Within five minutes. A vacuum
was applied to remove trapped gases and volatiles from the sample.
After 2 hours and 25 minutes, pressure was raised to atmospheric
with nitrogen gas at a constant flow rate of approximately 180
cc/min. The liquid samples were removed from the oven and
redistributed evenly over the entire Teflon.TM. mold bottom surface
by gently "rocking" the Teflon.TM. mold. The nitrogen gas flow rate
and temperature were maintained at approximately 180 cc/min and
polymerization continued at 130.degree. C. for 3,900 minutes. The
nitrogen gas flow then was terminated and pressure was again
reduced. Polymerization continued for 4,320 minutes under these
conditions. The temperature was decreased to ambient over several
hours. After increasing pressure to atmospheric, the product was
removed from the Teflon.TM. mold to yield four 125 mm diameter
disks that were approximately 1 mm thick.
[0184] The product was not soluble in acetone, but swelled in
acetone. Upon cooling to 23.degree. C., the product was not
optically clear. Titration reflected residual acidity of 0.0671
meq. acid/gram. The final product exhibited shape memory behavior
when exposed to a temperature of between 35.degree. C. and
39.degree. C. during the shape memory testing procedure described
herein. The Young's modulus, E', was 48 MPa at 22.degree. C. and
9.0 MPa at 37.degree. C. Results of differential scanning
calorimetry (DSC), mechanical and shape recovery experiments are
shown in FIG. 18. The glass transition temperature, T.sub.g, was
found to be about -37.degree. C. upon heating from -80.degree. C.
at 2.degree. C./min.
[0185] When tested in accordance with the cytotoxicity testing
described herein, the final product was found to be nontoxic-grade
1 to mammalian cells.
[0186] The material of example 1 was tested in vivo. Samples were
surgically implanted in longissimus dorsi muscle of New Zealand
White rabbits. The procedure of ISO 10933: Part 6 was followed.
Prior to implantation, the material was sterilized by gamma
radiation at 16-18 kGy. After implantation for 45 days, the muscle
was surgically removed and fixed in 10% neutral buffered
FORMALIN.RTM.. The muscle was sectioned, stained and examined
microscopically. No histological evidence of adverse tissue
reaction was found at any of the implant sites, suggesting the
material was biocompatible. No evidence of the implants was
found.
Comparative Example 2
[0187] 202.25 grams sebacic acid and 62.07 grams ethylene glycol
were combined in a 500 ml glass reactor. The reactor was equipped
with agitation, heating, vapor condensing, liquid volume measuring,
temperature regulating, temperature measuring and nitrogen gas
purging capabilities.
[0188] At room temperature, the reactants formed a heterogeneous
mixture of solid and liquid phase. As temperature was increased to
about 145.degree. C., the mixture became a homogeneous liquid. Time
and process parameters were recorded when all material was a single
phase liquid. Byproduct water vapor evolving from the reactor was
condensed and collected as described in Example 1. Total byproduct
water was 32.9 cc. 227 grams of the white brittle intermediate
reaction product, corresponding to 98.1% of the theoretical yield,
were produced. Titration reflected a residual acidity of 0.7119
meq. acid/gram. The product was partially soluble in acetone at
22.degree. C., and slightly more so at 50.degree. C., and was
completely soluble in dimethyl sulfoxide at 70.degree. C. and
completely soluble in hexaflouorispropanol (HFIP) at 22.degree.
C.
[0189] A 125 mm diameter Teflon.TM. mold was charged with 25.6
grams of the intermediate reaction product prepared as described
above. The mold containing the intermediate was placed in a vacuum
oven with the temperature set at 126.degree. C. The pressure was
initially set at atmospheric pressure. The solid intermediate
melted to form a clear viscous liquid within ten minutes.
Temperature was maintained at 125.degree. C. and pressure reduced.
After 4,320 minutes, oven pressure was raised to atmospheric and
cooled to ambient temperature over several hours.
[0190] Upon cooling the product was not optically clear. The
product was partially soluble in acetone at 50.degree. C., but less
so than the intermediate reaction product described above in this
Example. The product was completely soluble in dimethyl sulfoxide
at 70.degree. C. and in HFIP at 22.degree. C. Titration reflected a
residual acidity of 0.4563 meq. acid/gram. The final product did
not exhibit shape memory behavior.
[0191] The final product was brittle and no mechanical properties
could be evaluated at 22.degree. C. or at 37.degree. C. Upon
heating to a temperature above the product's melting point, the
product transformed to a viscous fluid.
Comparative Example 3
[0192] 202.25 grams sebacic acid and 92.09 grams glycerol were
combined in a 500 ml glass reactor. The reactor was equipped with
agitation, heating, vapor condensing, liquid volume measuring,
temperature regulating, temperature measuring and nitrogen gas
purging capabilities.
[0193] At room temperature the reactants formed a heterogeneous
mixture of solid and liquid phase. As temperature was increased to
about 153.degree. C., the mixture became a homogeneous liquid. Time
and process parameters were recorded when all material was a single
phase liquid. Byproduct water vapor evolving from the reactor was
condensed and collected as described in previous examples. A total
of 31.6 cc water was collected.
[0194] 259 grams of the solid product were recovered corresponding
to 98.6% of the theoretical yield. Upon cooling to ambient
temperature, the product formed an optically clear, very tacky
viscous fluid. The product was further cooled using dry ice and
formed a solid that was not optically clear. The intermediate
reaction product was completely soluble in acetone. Titration
reflected a residual acidity of 0.764 meq. acid/gram.
[0195] A 125 mm diameter Teflon.TM. crystallizing dish was charged
with 25.5 grams of the intermediate reaction product prepared as
described above. This was placed in a vacuum oven with the
temperature set at 126.degree. C. The pressure was initially set at
atmospheric pressure. A decrease in the viscosity of the product
was observed. After 10 minutes, pressure was reduced and
temperature of 125.degree. C. was maintained for 4,320 minutes. The
temperature then was decreased to ambient over three hours and
pressure was raised to atmospheric. The final product was removed
from the Teflon.TM. mold to yield a 125 mm diameter disk that was
approximately 2 mm thick.
[0196] Upon cooling, the final product was optically clear. It was
not soluble in acetone, but swelled in acetone. Titration yielded a
residual acidity of 0.058 meq. acid/gram.
[0197] The final product did not exhibit shape memory behavior when
subjected to the shape memory test procedure described herein. The
Young's modulus, E', was 2.1 MPa at 22.degree. C. and 2.1 MPa at
37.degree. C.
Example 4
[0198] 67.3 grams of the intermediate prepared and described in
Comparative Example 2 and 32.7 grams of the intermediate prepared
and described in Comparative Example 3 were combined in a 4 ounce
glass jar, and placed in a vacuum oven at 125.degree. C. and
atmospheric pressure. A 125 mm diameter Teflon.TM. crystallizing
dish and a laboratory mixing propeller assembly also were placed in
the oven at this time. After three hours, the glass jar and its
liquid intermediate contents were removed from the oven and
immediately placed in an appropriate sized heating mantle, a
thermocouple inserted into the molten mass and the temperature
maintained at 125.+-.5.degree. C. for five minutes. The
intermediates then were mixed at moderate speed for five minutes
until they appeared thoroughly mixed and formed a visibly
homogeneous single-phase liquid. 25 grams of the liquid was
transferred to the preheated Teflon.TM. crystallizing dish, and
placed back in the vacuum oven at 125.degree. C. and atmospheric
pressure. The pressure was reduced and polymerization continued for
4,260 minutes. Then the pressure was increased to atmospheric and
the mold and polymer removed from the oven and placed on a
laboratory benchtop at 22.degree. C. to cool. After one hour, it
was removed from the mold yielding a disk of approximately 2 mm
thickness.
[0199] Upon cooling, the product was not optically clear. The
product swelled in acetone at 50.degree. C., swelled in HFIP at
22.degree. C. and swelled in dimethyl sulfoxide at 70.degree. C.
Titration reflected a residual acidity of 0.2293 meq. acid/gram.
The product exhibited shape memory behavior when exposed to a
temperature of between 60.degree. C. and 66.degree. C. during the
shape memory testing procedure described herein. The Young's
modulus, E', was 278 MPa at 22.degree. C. and 160 MPa at 37.degree.
C. When tested in accordance with the cytotoxicity testing
described herein the product was nontoxic grade 0 to mammalian
cells.
Example 5
[0200] 46.8 grams of the intermediate prepared and described in
Comparative Example 2 and 53.2 grams of the intermediate prepared
and described in Comparative Example 3 were combined in a 4 ounce
glass jar.
[0201] The glass jar containing these intermediates was placed in a
vacuum oven at 125.degree. C. and atmospheric pressure. A 125 mm
diameter Teflon.TM. crystallizing dish and a laboratory mixing
propeller assembly also were placed in the oven at this time. After
three hours, the glass jar and its liquid intermediate contents was
removed from the oven and immediately placed in an appropriate
sized heating mantle, a thermocouple inserted into the molten mass
and the temperature maintained at 125.+-.5.degree. C. for five
minutes. The intermediates then were mixed at moderate speed for
five minutes until the intermediates appeared thoroughly mixed and
formed a visibly homogeneous single-phase liquid. 25 grams of the
liquid was transferred to the preheated Teflon.TM. crystallizing
dish, and placed back in the vacuum oven at 125.degree. C. and
atmospheric pressure. The pressure was reduced, and polymerization
continued for 4,260 minutes. Then the pressure was increased to
atmospheric and the mold and polymer removed from the oven and
placed on a laboratory benchtop at 22.degree. C. to cool.
[0202] While cooling, the product was not optically clear. After
one hour it was removed from the mold yielding a disk of nominally
2 mm thickness. The product swelled in acetone at 22.degree. C.
Titration reflected a residual acidity of 0.1209 meq. acid/gram.
The product exhibited shape memory behavior when exposed to a
temperature of between 40.degree. C. and 52.degree. C. during the
shape memory testing procedure described herein. The Young's
modulus, E', was 107 MPa at 22.degree. C. and 20.7 MPa at
37.degree. C. When tested in accordance with the cytotoxicity
testing described herein the product was nontoxic grade 0 to
mammalian cells.
Example 6
[0203] The procedures detailed in Example 4 and Example 5 were
repeated with 27.4 grams of the intermediate prepared as described
in Comparative Example 2 and 72.6 grams of the intermediate
prepared and described in Comparative Example 3 as starting
ingredients.
[0204] After cooling for one hour in the mold, the product was
removed from the mold yielding a disk of nominally 2 mm thickness.
It was optically clear. Within 24 hours at 22.degree. C., the
product was no longer optically clear. The product swelled in
acetone at 22.degree. C. Titration reflected a residual acidity of
0.1052 meq. acid/gram. The product exhibited shape memory behavior
when exposed to a temperature of between 32.degree. C. and
45.degree. C. during the shape memory testing procedure described
herein. The Young's modulus, E', was 7.2 MPa at 22.degree. C. and
2.6 MPa at 37.degree. C. When tested in accordance with the
cytotoxicity testing described herein the product was nontoxic
grade 0 to mammalian cells.
Example 7
[0205] The following components were placed into a 250 ml glass
beaker: 35.0 grams sebacic acid, 8.59 grams ethylene glycol, and
3.19 grams glycerol. The beaker and its contents were placed in a
vacuum oven set at 130.degree. C. A 100 mm diameter Petri dish that
was treated with a Teflon.TM. mold release agent was also placed in
the oven to preheat it. The initially heterogeneous solid-liquid
mixture transformed to a low viscosity fluid over the course of two
hours. After four hours, the fluid mixture was mixed with a
magnetic stirrer for three minutes and then poured into the
preheated Petri dish. The Petri dish and sample were placed in a
vacuum oven set at 130 CC. A vacuum was applied and polymerization
continued for 4,320 minutes. Then the oven power was turned off and
the oven and product allowed to cool while maintaining reduced
pressure. When the product cooled to ambient temperature, the
pressure was increased to atmospheric. The product was removed from
the Petri dish to yield a disk of nominally 2 mm thickness.
[0206] Upon cooling to 21.degree. C., the product was not optically
clear. It was not soluble in acetone, but it swelled in acetone.
Titration reflected a residual acidity of 1.450 meq. acid/gram. The
product exhibited shape memory behavior when exposed to a
temperature of between 51.degree. C. and 55.degree. C. during the
shape memory testing procedure described herein.
Example 8
[0207] The procedure detailed in Example 7 was repeated with the
following starting ingredients: 35.0 grams sebacic acid, 8.06 grams
ethylene glycol, and 3.98 grams glycerol.
[0208] Upon cooling to 21.degree. C., the product was not optically
clear. It was not soluble in acetone, but it swelled in acetone.
Titration reflected a residual acidity of 0.7091 meq. acid/gram.
The product exhibited shape memory behavior when exposed to a
temperature of between 40.degree. C. and 48.degree. C. during the
shape memory testing procedure described herein.
Example 9
[0209] The procedure detailed in Example 7 was repeated with the
following ingredients: 35.0 grams sebacic acid, 7.52 grams ethylene
glycol, and 4.78 grams glycerol.
[0210] Upon cooling to 21.degree. C., the product was not optically
clear. It was not soluble in acetone, but it swelled in acetone.
Titration reflected a residual acidity of 0.6899 meq. acid/gram.
The product exhibited shape memory behavior when exposed to a
temperature of between 35.degree. C. and 41.degree. C. during the
shape memory testing procedure described herein.
Example 10
[0211] The following components were placed into a 400 ml glass
beaker: 50.0 grams sebacic acid, 10.74 grams ethylene glycol and
6.83 grams glycerol. The beaker was loosely covered with aluminum
foil and its contents were placed in a vacuum oven set at
125.degree. C. The initially heterogeneous solid-liquid mixture
transformed to a low viscosity fluid over the course of two hours.
The fluid mixture was mixed with a magnetic stirrer for two minutes
and then returned to the vacuum oven at 125.degree. C. A vacuum was
applied, and polymerization continued for 1,000 minutes before the
pressure was increased to atmospheric and the sample was
mechanically stirred for two minutes. The vacuum of was reapplied
for 50 minutes. The mixture then was transferred to two 125 mm
preheated Teflon.TM. crystallizing dishes. One dish contained about
30 grams of sample, while the other contained about 23 grams. The
samples were returned to the vacuum oven under reduced pressure and
set at about 130.degree. C. These conditions were maintained for
3,100 minutes. The oven power then was turned off and the oven and
product cooled to 28.degree. C. while maintaining reduced pressure.
Pressure then was increased to atmospheric and the product removed
from the oven and the crystallizing dishes to yield two disks of
nominally 2 mm thickness.
[0212] Upon cooling to ambient temperature, the product was not
optically clear. It was not soluble in acetone, but it swelled in
acetone. Titration reflected a residual acidity of 0.7591 meq.
acid/gram. The product exhibited shape memory behavior when exposed
to a temperature of between 34.degree. C. and 38.degree. C. during
the shape memory testing procedure described herein. When tested in
accordance with the cytotoxicity testing described herein, the
product was found to be cytotoxic to mammalian cells Grade=4.
Example 11
[0213] A 125 mm diameter Teflon.TM. crystallizing dish was charged
with 10.0 grams of the intermediate reaction product of Example 1.
The dish containing the semicrystalline intermediate was placed in
a vacuum oven at 130.degree. C. After fifteen minutes, the liquid
intermediate was distributed evenly over the dish surface by gently
rocking the dish thereby causing the liquid intermediate to flow
and cover the entire dish bottom surface. Nitrogen gas was charged
to the oven at a relatively high rate while the temperature was
maintained at 130.degree. C. After polymerizing for 2,400 minutes
under these conditions, the nitrogen gas flow was stopped and the
pressure was reduced. After polymerizing for 1,440 minutes under
these conditions, the pressure was increased to atmospheric and the
dish containing the polymerized product was removed from the vacuum
oven and placed on a lab benchtop at 22.degree. C. to cool.
[0214] Upon cooling, the product was not optically clear. The
product was not soluble in acetone, but it swelled in acetone.
Titration reflected a residual acidity of 0.2170 meq. acid/gram.
The final product exhibited shape memory behavior when exposed to a
temperature of between 42.degree. C. and 48.degree. C. during the
shape memory testing procedure described herein.
[0215] Shape memory behavior was also demonstrated in this product
by "cold drawing" the sample at ambient temperature (about
21.degree. C.). The product was found to yield when stretched in
uniaxial tension or when deformed by bending. It yielded at a
uniaxial tensile strain of about 0.10 when stretched at a rate of
25.4 mm/min. The sample was subjected to an elongation of 100% and
retained its deformed shape and dimensions after the deforming
force was removed. The cold drawn deformed product then was heated
to 57.degree. C. Within 30 seconds, the product's original
undeformed shape and dimensions were recovered.
Example 12
[0216] The procedure described in Example 1 was repeated with the
following ingredients: 101.125 grams sebacic acid, 21.730 grams
ethylene glycol and 13.81 grams glycerol.
[0217] At room temperature the reactants formed a heterogeneous
mixture of solid and liquid phases. As temperature was increased to
about 149.degree. C., the mixture became a homogeneous liquid. Time
and process parameters were recorded when all material was a single
phase liquid. Byproduct water vapor evolving from the reactor was
condensed and collected in a volumetric receiving tube graduated in
0.1 cc increments. In total, 15.9 cc of water was collected. The
intermediate reaction product was 117 grams of white waxy material,
corresponding to 96.9% of the theoretical yield. While cooling to
ambient temperature, the product was not optically clear. Titration
reflected a residual acidity of 0.522 meq. acid/gram. The
intermediate reaction product was soluble in acetone at room
temperature.
[0218] The second stage polymerization was performed by placing a
charge of 19.4 grams of the intermediate reaction product prepared
as described above, into 125 mm diameter Teflon.TM. crystallizing
dish at 22.degree. C. The Teflon.TM. mold containing the
intermediate was placed in a vacuum oven with the temperature set
at 120.degree. C. The pressure was initially set at atmospheric
pressure. The solid semicrystalline intermediate melted to form a
clear viscous liquid within fifteen minutes. The liquid was
distributed over the dish by rocking it. Pressure then was reduced.
After 1,080 minutes, oven pressure was raised to atmospheric and a
small sample (sample 1) was taken before the product was returned
to the vacuum oven under reduced pressure and at 120.degree. C. The
sampling process was repeated at 1,440 minutes (sample 2), 2,460
minutes (sample 3) and 5,305 minutes (sample 4) total time. The
residual acidity for each sample is reported in Table 1, below.
[0219] Upon cooling to 23.degree. C., the samples were not
optically clear. All were insoluble in acetone, but swelled in
acetone. All four samples exhibited shape memory behavior. When
tested in accordance with the cytotoxicity testing described
herein, Sample 4 was found to be nontoxic, Grade=0 to mammalian
cells.
TABLE-US-00001 TABLE 1 Polymerization Time Cumulative Segment
Residual Acidity Time (min.) Time (min.) (meq./gram) 1080 1080
0.2586 1440 360 0.2582 2460 1020 0.1157 5305 2845 0.0909
Example 13
[0220] An intermediate reaction product was prepared according to
the process described in Example 1, above. The reactants consisted
of 101.125 grams sebacic acid, 21.730 grams ethylene glycol and
13.81 grams glycerol. Upon heating, the reactants formed a
homogeneous liquid at 165.degree. C. A total of 13.2 cc byproduct
water was collected.
[0221] Upon cooling to ambient temperature, the intermediate
reaction product became a white waxy material that was not
optically clear. 120 grams of intermediate was recovered, which
corresponds to 97.2% of the theoretical yield. The intermediate
reaction product was soluble in acetone. Titration reflected a
residual acidity of 1.518 meq. acid/gram.
[0222] A 125 mm Teflon.TM. crystallizing dish was charged with 35
grams of the intermediate reaction product at room temperature. The
sample was placed in an oven at 120.degree. C. under vacuum. The
sample was polymerized for 13,968 minutes before cooling and
raising pressure to ambient conditions of 22.degree. C.
[0223] Upon cooling, the product was not optically clear. It was
insoluble in acetone, but swelled in acetone. Titration reflected a
residual acidity of 0.0280 meq. acid/gram. The product exhibited
shape memory behavior when exposed to a temperature of 37.degree.
C. When tested in accordance with the cytotoxicity testing
described herein, it was nontoxic, Grade=0 to mammalian cells.
Example 14
[0224] A 125 mm Teflon.TM. crystallizing dish was charged with a 35
gram sample of the intermediate reaction product prepared according
to the method of Example 13. Polymerization was conducted at a
temperature of 120.degree. C. and under a vacuum for 5,760 minutes.
The sample was removed from the oven and cooled at ambient
temperature to 22.degree. C.
[0225] Upon cooling, the product was not optically clear. It was
insoluble in acetone, but swelled in acetone. Titration reflected a
residual acidity of 0.2294 meq. acid/gram. The product exhibited
shape memory behavior when exposed to a temperature of 37.degree.
C. When tested in accordance with the cytotoxicity testing
described herein, the product was nontoxic, Grade=0 to mammalian
cells.
Example 15
[0226] The final product of Example 12 (Sample 4) was sterilized by
gamma radiation at a dose of 25 kGy. Titration reflected a residual
acidity of 0.0960 meq. acid/gram. The product exhibited shape
memory behavior after sterilization when exposed to a temperature
of 37.degree. C. When tested in accordance with the cytotoxicity
testing described herein, the product was found to be nontoxic,
Grade=0, to mammalian cells.
Example 16
[0227] A semicrystalline intermediate reaction product having a
residual acidity of 0.8690 meq. acid/gram was prepared according to
the procedure described in Example 1.
[0228] A 125 mm diameter Teflon crystallizing dish was charged with
8.3 grams of this intermediate and placed in a vacuum oven at a
temperature of 140.degree. C. The vacuum oven pressure was equal to
atmospheric pressure. The semicrystalline intermediate melted to a
clear viscous liquid within five minutes and a vacuum applied.
Polymerization continued under these conditions for 5,460 minutes.
The pressure then was increased to atmospheric and the Teflon.TM.
dish and its contents were removed from the vacuum oven and placed
on a lab benchtop to cool at 22.degree. C.
[0229] Upon cooling, the product was optically clear. The product
was not soluble in acetone, but it swelled in acetone. Titration
reflected a residual acidity of 0.0210 meq. acid/gram. The product
did not exhibit shape memory behavior when subjected to the shape
memory test procedure described herein.
Example 17
[0230] 25.0 grams sebacic acid (Aldrich, 99%), 1.918 grams ethylene
glycol (Aldrich, 99.8% anhydrous) and 8.5367 grams glycerol
(Aldrich, 99.5%+spectrophotometric grade) were placed into a 250 ml
glass beaker. The beaker and its contents were placed in a vacuum
oven set at 120.degree. C. A 100 mm diameter glass Petri dish was
also placed in the vacuum oven to preheat it. The inner surfaces of
the dish were treated with a Teflon.TM. mold release agent. The
initially heterogeneous solid-liquid mixture transformed to a low
viscosity fluid over the course of three hours. The fluid mixture
was mixed with a magnetic stirrer for several minutes and then it
was poured into the preheated Petri dish and placed back in the
vacuum oven at 120.degree. C. under reduced pressure.
Polymerization was continued under these conditions for 4,080
minutes. The pressure then was increased to atmospheric and the
oven and product cooled to 23.degree. C.
[0231] Upon cooling to ambient temperature, the product was
optically clear. The product was not soluble in acetone, but it
swelled in acetone. Titration reflected a residual acidity of
0.2064 meq. acid/gram. The product did not exhibit shape memory
behavior when subjected to the shape memory test procedure
described herein.
Example 18
[0232] Additional samples of the crosslinked polymer compositions
were prepared using alternative diols. The following monomer
components were placed into a 0.5 liter glass reactor: 101.25 grams
sebacic acid (Aldrich, 99%), 28.54 grams 1,3-propanediol (Aldrich,
99.6%+anhydrous), and 11.51 grams glycerol (Aldrich,
99.5%+spectrophotometric grade). The reactor was equipped with
agitation, heating, vapor condensing, liquid volume measuring,
temperature regulating, temperature measuring and nitrogen gas
purging capabilities. The procedure described in Example 1 was
followed.
[0233] Initially, the reactants formed a heterogeneous solid/liquid
mixture at room temperature. As temperature was increased, the
reactants became a homogeneous liquid mixture at about 117.degree.
C. Time and process parameters were recorded when all material in
the reactor formed a single phase liquid. Water vapor was condensed
and collected in a volumetric receiving tube graduated in 0.1 cc
increments. In total, 14.0 cc of water was collected.
[0234] Upon cooling to ambient temperature, the intermediate
reaction product was not optically clear. 123.3 grams of a white
waxy intermediate reaction product, corresponding to a 96.9% yield,
was recovered in the first stage of polymerization. The
intermediate reaction product was soluble in acetone. Titration
reflected a residual acidity of 1.0528 meq. acid/gram.
[0235] In the second polymerization stage, a charge of 20.0 grams
of the intermediate reaction product was placed into a 125 mm
diameter Teflon.TM. crystallizing dish at 22.degree. C. This was
placed in a vacuum oven with the temperature set at 120.degree. C.
and pressure equal to atmospheric pressure. The solid
semicrystalline intermediate melted to a clear viscous liquid
within five minutes before pressure was reduced. Polymerization
continued for 6,060 minutes under these conditions, before the
temperature was decreased to 22.degree. C.
[0236] After increasing the pressure to atmospheric, the product
was removed from the Teflon.TM. mold yielding a disk of 125 mm
diameter of nominally 2 mm thickness. Upon cooling, the product was
not optically clear. The product was not soluble in acetone, but it
swelled in acetone. Titration reflected a residual acidity of 0.174
meq. acid/gram. The product exhibited shape memory behavior when
exposed to a temperature of between 42.degree. C. and 47.degree. C.
during the shape memory testing procedure described herein.
Example 19
[0237] The following monomer components were placed into a 0.5
liter glass reactor: 101.25 grams sebacic acid (Aldrich, 99%),
33.75 grams 1,4-butanediol (Aldrich, Reagent Plus >99%) and
11.51 grams glycerol (Aldrich, 99.5%+spectrophotometric grade). The
reactor was equipped with agitation, heating, vapor condensing,
liquid volume measuring, temperature regulating, temperature
measuring and nitrogen gas purging capabilities. The procedure
described in Example 1 was followed.
[0238] Initially, the reactants formed a heterogeneous solid/liquid
mixture at room temperature. As temperature was increased, the
reactants became a homogeneous liquid mixture at about 118.degree.
C. Time and process parameters were recorded when all material in
the reactor formed a single phase liquid. The water vapor was
condensed and collected in a volumetric receiving tube graduated in
0.1 cc increments. In total, 13.5 cc of water was collected.
[0239] Upon cooling to ambient temperature, the intermediate
reaction product was not optically clear. 130.5 grams of a white
waxy intermediate reaction product was collected, corresponding to
a 98.1% yield. The intermediate reaction product was soluble in
acetone. Titration reflected a residual acidity of 1.1276 meq.
acid/gram.
[0240] In the second stage, a charge of 29.3 grams of the
intermediate reaction product was placed into a 125 mm diameter
Teflon.TM. crystallizing dish at 22.degree. C. This was placed in a
vacuum oven with the temperature set at 120.degree. C. and a vacuum
was applied. The solid semicrystalline intermediate melted to a
clear viscous liquid within four hours. Polymerization continued
for 5,760 minutes under these conditions, before the temperature
was decreased to 22.degree. C.
[0241] Upon cooling, the product was not optically clear. After
increasing the pressure to atmospheric, the product was removed
from the Teflon.TM. mold yielding a disk of 125 mm diameter of
nominally 2 mm thickness. The product was not soluble in acetone,
but it swelled in acetone. Titration reflected a residual acidity
of 0.2344 meq. acid/gram. The product exhibited shape memory
behavior when exposed to a temperature of between 49.degree. C. and
51.degree. C. during the shape memory testing procedure described
herein.
Example 20
[0242] 26.0 grams sebacic acid (Aldrich, 99%), 5.59 grams ethylene
glycol (Aldrich, 99.8% anhydrous) and 3.55 grams glycerol (Aldrich,
99.5%+spectrophotometric grade) were combined in a 250 ml glass
beaker. The beaker was loosely covered with aluminum foil and
placed in a vacuum oven set at 127.degree. C. The heterogeneous
reaction mixture transformed to a homogeneous liquid after 165
minutes. After an additional 240 minutes, 22.7 grams of the liquid
reactive mixture was transferred from the 250 ml glass beaker into
a 1,000 ml glass beaker that was preheated and treated with
Teflon.TM. mold release agent. Sodium chloride (NaCl) crystals
(187.5 grams) were poured onto the liquid phase, thereby creating a
salt bed through which the low viscosity liquid phase percolated.
The solids volume fraction of the sodium chloride phase was about
0.85. Pressure was reduced and temperature was increased to
127.degree. C. The polymerization continued under these conditions
for 5,305 minutes. Then the oven power was turned off and the
material cooled to 22.degree. C. under vacuum.
[0243] The sodium chloride was extracted from the intermediate
reaction product by rinsing with reverse osmosis water
(conductivity<5 microsiemens/cm) until the water washings had a
conductivity less than 400 microsiemens/cm. The porous reaction
product was now compliant when probed with a finger. The cellular
void space of the porous reaction product was filled with
water.
[0244] The water-wet intermediate reaction product was placed in a
vacuum oven at 22.degree. C. and pressure was decreased with a
vacuum pump to dry it to a constant weight. After drying in this
manner, 19.7 grams of the dried product was collected, which
corresponds to an approximately 100% yield after accounting for
byproduct water from the polymerization operation. The porous
reaction product was disk shaped and approximately 16 mm thick.
[0245] The final foam product has a density equal to 0.17.+-.0.02
g/cc, indicating that the product was about 85% by volume void
space. It was examined with a scanning electron microscope (SEM)
and the cellular geometry resembled the sodium chloride crystal
shapes and dimensions as shown in FIG. 19. Differential scanning
calorimetry (DSC) showed that the foam product had a glass
transition temperature, T.sub.g, of about -35.degree. C., was
semicrystalline at 22.degree. C., and was totally amorphous at
temperatures above 36.degree. C. The foam product was not soluble
in acetone, but it swelled in acetone. Titration with potassium
hydroxide indicated residual acidity of 1.0280 meq. acid/gram. The
foam product exhibited shape memory behavior in a 37.degree. C.
water bath.
Example 21
[0246] 101.125 grams sebacic acid (Aldrich, 99%), 21.730 grams
ethylene glycol (Aldrich, 99.8% anhydrous) and 13.81 grams glycerol
(Aldrich, 99.5%+spectrophotometric grade) were polymerized
according to the procedures described in first polymerization stage
of Example 1 to form an intermediate reaction product. The
intermediate reaction product had a residual acidity of 0.522 meq.
acid/gram. 20.0 grams of the intermediate reaction product was
combined with 40.0 grams of acetone in a four ounce glass jar at
23.degree. C. The mixture then was stirred with a magnetic stirrer
and a clear homogeneous low viscosity intermediate-acetone solution
formed within one hour.
[0247] 185.0 grams of sodium chloride (NaCl) crystals was poured
into a 125 mm diameter Teflon.TM. crystallizing dish and
distributed to create a uniformly thick salt bed through which a
low viscosity liquid phase could percolate. The Teflon.TM.
crystallizing dish and salt bed were placed in a 120.degree. C.
vacuum oven and pressure was decreased to dry the salt bed for two
hours. The salt bed was removed from the vacuum oven and placed in
a 45.degree. C. forced air oven for an additional two hours of
drying.
[0248] The intermediate-acetone solution was poured onto the salt
bed. The intermediate-acetone solution percolated through the salt
bed. A total of 57.1 grams of the 33.33% by weight intermediate
solution was transferred and its volume occupied the salt bed void
space and an excess volume layer sat above the salt bed. The
acetone was evaporated at 45.degree. C. The intermediate-imbibed
salt bed was transferred from the 45.degree. C. forced air oven to
a 120.degree. C. vacuum oven and pressure was reduced. These
polymerization conditions were maintained for 1,500 minutes before
the crosslinked polymer imbibed salt bed sample was removed from
the vacuum oven and placed in a refrigerator at 0.degree. C. After
one hour, the sample was removed from the refrigerator and placed
on a lab benchtop at 23.degree. C. The sample was removed from the
Teflon.TM. crystallizing dish, and was found to be stiff to the
touch.
[0249] The sodium chloride was extracted from the intermediate
composite by washing with reverse osmosis water (conductivity<5
microsiemens/cm) at 21.degree. C. until the water washings also had
a conductivity less than 5 microsiemens/cm. With the salt removed,
the sample was compliant when probed.
[0250] The water-wet porous intermediate reaction product was dried
overnight, then vacuum dried at 37.degree. C. for four hours, and
then polymerized in a vacuum oven at 120.degree. C. and pressure
reduced. Polymerization continued under these conditions for an
additional 7 days. The foam product was removed from the oven and
placed on a lab benchtop at 22.degree. C. to cool. The dry foam
final product was a 10 mm thick disk weighing 17.5 grams.
[0251] The cooled foam had a density equal to 0.15+.+-.0.02 g/cc,
indicating that the product had about 85% by volume void space. The
foam product was not soluble in acetone, but it swelled in acetone.
Titration reflected a residual acidity of 0.1000 meq.
acid/gram.
[0252] When tested in accordance with the cytotoxicity testing
described herein, the foam product was found to be nontoxic,
grade=0 to mammalian cells. The foam product exhibited shape memory
behavior. A right circular cylinder of the foam was deformed by
biaxial compression at 45.degree. C. and subsequently cooled to
22.degree. C. The foam maintained this deformed shape for 21 hours
then, when subsequently heated to 45.degree. C., the foam exhibited
shape memory behavior.
Example 22
[0253] A further example of the foam compositions was prepared
according to the procedure similar to that described in Example 21.
The monomer components were 202.25 grams of sebacic, acid (Aldrich,
99%), 43.46 grams ethylene glycol (Aldrich, 99.8% anhydrous) and
26.26 grams glycerol (Aldrich, 99.5%+spectrophotometric grade). The
intermediate reaction product had a residual acidity of 0.5547 meq.
acid/gram.
[0254] 20 grams of the intermediate reaction product was combined
with 70 grams of acetone, and the resulting intermediate/acetone
solution (75.8 grams) was poured onto a salt bed comprising 138
grams of salt having a particle size of less than 70 mesh and a
bulk density of 0.945 g/cc. The acetone was evaporated at
45.degree. C. for 24 hours.
[0255] The intermediate-imbibed salt bed was further polymerized at
137.degree. C. and under vacuum for 2,880 minutes. The sodium
chloride was extracted by rinsing with reverse osmosis water as in
the previous examples.
[0256] The resulting foam had a density of 0.24 g/cc, indicating
that it was comprised of about 75% void space. The product was not
soluble in acetone, but swelled in acetone. Titration reflected
residual acidity of 0.2005 meq. acid/gram.
[0257] The foam also was examined by DSC and was totally amorphous
at temperatures equal or above 38.degree. C. The crosslinked foam
exhibited shape memory behavior.
Example 23
[0258] A further example of the foam compositions was prepared
according to the procedure described in Example 21. The
intermediate reaction product had a residual acidity of 0.6712 meq.
acid/gram. The intermediate reaction product was combined with
acetone and the resulting intermediate/acetone solution was poured
onto a salt bed (Aldrich, A.C.S. reagent grade >99.0%). The
procedures for acetone evaporation, polymerization, salt
extraction, water evaporation and further polymerization described
in Example 21 were followed to produce 19 grams of crosslinked
polyester foam of density equal to 0.16 g/cc. The crosslinked foam
exhibited shape memory behavior at 37.degree. C.
Example 24
[0259] 20.3 grams of the intermediate of Example 16 was combined
with 40.0 grams of acetone in a four ounce glass jar at 21.degree.
C. A magnetic stir bar was added to the mixture; the jar was capped
and stirred with a magnetic stirrer until a clear homogeneous low
viscosity solution formed (within about one hour). The
intermediate-acetone solution was placed in a 45.degree. C. forced
air oven.
[0260] 185.0 grams of sodium chloride (NaCl) crystals was poured
into a 125 mm diameter Teflon.TM. crystallizing dish and
distributed to create a uniformly thick salt bed through which a
low viscosity liquid phase could percolate. The Teflon.TM.
crystallizing dish and salt bed were placed in a 40.degree. C.
vacuum oven and pressure decreased to dry the salt bed for about 3
hours.
[0261] The salt bed was removed from the vacuum oven, after
increasing the pressure to atmospheric, and 58.0 grams of the
intermediate-acetone solution was poured onto the salt bed. The
intermediate-acetone solution percolated through the salt bed and
occupied the salt bed void space and an excess volume layer sat
above the salt bed.
[0262] The crystallizing dish and its contents were placed in a
45.degree. C. forced air oven for 20 hours. Then, the
intermediate-imbibed salt bed was transferred to a 40.degree. C.
vacuum oven and a vacuum applied. These conditions were maintained
for 3 hours. Then the temperature was increased to 130.degree. C.
over the course of about 2 hours, and polymerization continued
under these conditions for an additional 5,520 minutes.
[0263] After increasing pressure to atmospheric pressure, the
Teflon.TM. crystallizing dish and polymer imbibed-salt bed removed
from the vacuum oven and cooled to 0.degree. C. After 1 hour, the
Teflon.TM. crystallizing dish and polymer imbibed salt bed was
warmed to 22.degree. C. Thereafter, the polymer imbibed salt bed
was removed from the Teflon.TM. crystallizing dish.
[0264] Next, the sodium chloride was extracted from the
intermediate composite by washing with reverse osmosis water
(conductivity<5 microsiemens/cm) at 22.degree. C. until the
water washings had a conductivity less than 30 microsiemens/cm.
With the salt removed, the sample was compliant when probed.
[0265] The water-wet intermediate product was air dried over 2
days, then vacuum dried for 19 hours at 37.degree. C. Then, the
pressure was increased to atmospheric and the foam product was
removed from the oven and cooled to 22.degree. C.
[0266] The dry foam product was recovered in the shape of a disk
having a thickness of nominally 10 mm. The foam had a density of
0.14 g/cc, indicating that the product was comprised of about 85%
by volume void space.
[0267] The foam product exhibited a crystalline melting point
(T.sub.m) in the range 2.degree. C.<T.sub.m<9.degree. C. The
foam product was not soluble in acetone, but it swelled in acetone.
The residual acidity was found to be 0.2377 meq/gram. The foam
product did not exhibit shape memory behavior.
Example 25
[0268] An aqueous dye solution was prepared by combining 1.60 grams
Indigo Carmine crystals and 100 ml of reverse osmosis water at
22.degree. C. The resultant dye solution was transferred to a four
ounce glass jar. Several right circular cylinders of the dried foam
product of Example 23 having a diameter of about 5 mm were
transferred to the dye solution. In like manner, several right
circular cylinders of the dried foam product of Example 22 having a
diameter of about 4 mm were transferred to the dye solution. These
foam objects were alternately compressed and decompressed several
times to imbibe the foam with the dye solution. The jar containing
the solution and solution imbibed foam objects was capped and
placed in an oven at 50.degree. C. for one hour. Then the jar and
its contents were removed from the oven and placed in a lab hood at
22.degree. C. to cool. After an additional two hours, the
solution-imbibed foam objects were removed from the solution and
placed on aluminum weighting dishes and then transferred to a
50.degree. C. vacuum oven under reduced pressure to dry for 16
hours. Then pressure was increased to atmospheric and the dried
foam objects transferred to a lab hood at 22.degree. C. to cool.
After cooling, all foam objects were a deep blue color.
[0269] Several 4 mm diameter cylindrical samples of the porous
polymer, some containing Indigo Carmine dye and some undyed were
evaluated. The samples were placed between two aluminum plates with
their long axis parallel to the plates. The top plate was weighted
down by a large brass block. This metal and porous polymer assembly
were placed into a 60.degree. C. temperature chamber for 30
minutes. The temperature of the chamber was reduced to 0.degree. C.
and remained an additional 30 minutes. The temperature was
increased to 25.degree. C., and the metal and porous polymer
assembly was removed. The porous polymer samples were extracted
from between the aluminum plates and were now compressed to a
metastable state of approximately 1 mm in thickness.
[0270] The dyed, and non-dyed, compressed metastable porous samples
were irradiated with the frequency doubled Nd:YAG laser source. The
blue dye has a broad absorption band centered at approximately 600
nm. The wavelength of light emitted from a frequency doubled Nd:YAG
source is 532 nm. Measurements were previously made of the
blue-dyed foam's UV-VIS spectrum in a reflection mode and the
spectrum indicated that the blue-dyed foam was strongly absorptive
at 532 nm.
[0271] Each sample was placed into the beam path of the laser for
30 seconds. Three samples of blue-dyed foam were irradiated by the
laser in this manner. In each instance the blue-dyed foam
demonstrated uniform shape and dimensional recovery in response to
the laser stimulus.
[0272] Samples of non-dyed foam were, in like manner, irradiated
for 60 seconds as a control experiment. The undyed foam did not
demonstrate a dimensional shape recovery. As a further control
experiment, one sample of dyed and compressed porous polymer was
placed onto a hot plate to determine if shape recovery would occur.
This sample of foam expanded to a cylinder with a diameter of
approximately 4 mm demonstrating substantial recovery.
Example 26
[0273] 136.98 grams sebacic acid (Aldrich, 99%), 34.62 grams
ethylene glycol (Aldrich, 99.8% anhydrous) and 22.02 grams glycerol
(Aldrich, 99.5%+spectrophotometric grade) were combined in a glass
reactor. The reactor was equipped with agitation, heating, vapor
condensing, liquid volume measuring, temperature regulating,
temperature measuring and nitrogen gas purging capabilities.
[0274] Initially, the reactants formed a heterogeneous solid/liquid
mixture at room temperature. As temperature was increased, the
reactants became a homogeneous liquid mixture at about 127.degree.
C. Time and process parameters were recorded once all material in
the reactor formed a single phase liquid. Byproduct water vapor was
condensed and collected in a volumetric receiving tube graduated in
0.1 cc increments; 21.9 cc total water was collected. Upon cooling
to ambient temperature, the intermediate product formed was not
optically clear. The intermediate reaction product was soluble in
acetone. Titration reflected a residual acidity of 0.4305 meq.
acid/gram.
[0275] Three foam compositions then were prepared from this
uncrosslinked intermediate reaction product. The uncrosslinked
intermediate was melted and charged to three 50 ml plastic beakers.
To each beaker was added a quantity of 4,4'-methylenebis(phenyl
isocyanate), (MDI) (Huntsman, FW=250.26 grams/mole, MP=37.degree.
C., RUBINATE.RTM. 44) that had been heated to 50.degree. C., such
that the weight fraction of MDI in the first beaker was 0.15, the
weight fraction of the second was 0.25 and the third was 0.35. Each
then was mixed for 30 seconds with a centrifugal mixing apparatus
(Thinky AR250) and then placed in a 120.degree. C. oven for 40
minutes. The mixtures reacted and gas was generated in-situ,
resulting in the creation of three foam compositions.
[0276] Upon cooling to room temperature, it was apparent that all
three foams were stable. The foam volume increased as the weight
fraction of MDI in the composition increased.
[0277] The foam sample corresponding to a MDI weight fraction equal
to 0.15 was examined to probe its physical, mechanical and shape
memory properties. The sample was insoluble in acetone. The foam
was of the open cell kind. The foam density at 22.degree. C. was
about 0.35 grams/cc suggesting that it comprised about 65% by
volume air or void space.
[0278] The sample was heated from 20.degree. C. at a rate of
2.degree. C./min. It exhibited two endothermic transitions (T.sub.1
and T.sub.2) over the temperature range 30.degree.
C.<T.sub.1<42.degree. C. and 50.degree.
C.<T.sub.2<65.degree. C. The Young's modulus, E', was 7 MPa
at 25.degree. C. and 0.35 MPa at about 57.degree. C. The foam
sample demonstrated shape memory behavior at 85.degree. C.
Example 27
[0279] Another foam example was created from the intermediate
reaction product of 101.13 grams sebacic acid (Aldrich, 99%), 21.73
grams ethylene glycol (Aldrich, 99.8% anhydrous) and 13.81 grams
glycerol (Aldrich, 99.5%+spectrophotometric grade). During the
first stage polymerization, 15.0 cc water was collected. Upon
cooling to ambient temperature, the product was not optically
clear. It was soluble in acetone. Titration reflected a residual
acidity of 0.6712 meq. acid/gram.
[0280] Three foam compositions then were prepared from the
uncrosslinked intermediate reaction product. Following the
procedures described in Example 26, heated MDI (Huntsman, FW=250.26
grams/mole, MP=37.degree. C., RUBINATE.RTM. 44) was added to the
molten intermediate reaction product such that the weight fraction
of MDI in each of three beakers corresponded to 0.15 in the first
beaker, 0.25 in the second, and 0.35 in the third. These
combinations then were mixed with a centrifugal mixing apparatus
(Thinky AR250) for 30 seconds and then placed in a 120.degree. C.
oven for 40 minutes. During this time, the mixtures reacted and gas
was generated in-situ, resulting in the creation of three foam
compositions.
[0281] Upon cooling to room temperature, all three of the foams
were stable. The foam volume increased as the weight fraction of
MDI in the composition increased.
Example 28
[0282] Another foam example was created from the intermediate
reaction product of 202.25 grams sebacic acid (Aldrich, 99%), 36.93
grams ethylene glycol (Aldrich, 99.8% anhydrous) and 23.48 grams
glycerol (Aldrich, 99.5%+spectrophotometric grade). During the
first stage polymerization, 27.4 cc water was collected. Upon
cooling to ambient temperature the product was optically not clear.
The intermediate was soluble in acetone.
[0283] Three foam compositions then were prepared from the
uncrosslinked intermediate reaction product. Following the
procedures described in Example 26, heated MDI (Huntsman, FW=250.26
grams/mole, MP=37.degree. C., RUBINATE.TM. 44) was added to molten
intermediate reaction product such that the weight fraction of MDI
in each of beaker corresponded to 0.15, 0.25 or 0.35. These
combinations then were mixed with a centrifugal mixing apparatus
(Thinky AR250) for 30 seconds and then placed in a 120.degree. C.
oven for 40 minutes. During this time, the mixtures reacted and gas
was generated in-situ resulting in the creation of three foam
compositions.
[0284] Upon cooling to room temperature, all three of the foams
were stable. The foam volume increased as the weight fraction of
MDI in the composition increased.
Example 29
[0285] The uncrosslinked intermediate reaction product of Example
21 was added to a glass vessel containing acetone such that the
intermediate reaction product concentration was six percent by
weight. The mixture then was heated to 45.degree. C. and stirred.
Within four hours, a homogeneous solution was obtained. The
solution was removed from the heat source and cooled to room
temperature.
[0286] An ePTFE nonwoven web was imbibed with the solution to form
a composite prepreg. The ePTFE nonwoven was made in accordance with
the teachings of Bacino, U.S. Pat. No. 5,476,589. A wire wound rod
coating process was used to imbibe the ePTFE. The intermediate
polymer solution was fed directly onto the unsupported ePTFE
nonwoven web. and was metered with a #29 wire wound coating rod.
The line speed was 3 m/min. and the wrap angle was approximately
145 degrees on the coating rod. As the solution was being applied,
an ACCUPLY backing material (obtained from Accurate Plastics,
Yonkers, N.Y.) was applied to the ePTFE web such that the polymer
solution coated side was oriented towards the backing material.
After imbibing the ePTFE with the polymer intermediate solution,
the acetone was evaporated in a convection oven.
[0287] Using the same process settings, the opposite side of the
ePTFE nonwoven web was coated with polymer intermediate solution.
In this second coating step, a #8 wire wound rod was used to coat
the exposed ePTFE. After coating, the acetone was evaporated in a
convection oven.
[0288] A multi-layer composite structure was fabricated by wrapping
the composite prepreg tape onto a stainless steel mandrel. The
mandrel cross-section was essentially square; it had four flat
sides measuring 30 mm by 60 mm. The intermediate corners were each
rounded to a 5 mm arc. A fluorinated ethylene propylene (FEP)
release film was first applied to the mandrel to prevent the
prepreg composite tape from bonding to the mandrel. The prepreg
composite tape was applied to the mandrel while the mandrel rotated
at a speed of 10 rpm. The process continued for 8 minutes to create
a multilayer composite structure consisting of eighty layers of the
prepreg composite tape.
[0289] The mandrel and composite assembly then was placed in a
vacuum oven at 135.degree. C. and vacuum applied. The imbibed
polymer intermediate was further polymerized for 5,040 minutes
under these conditions before the temperature was reduced to
approximately 22.degree. C. and the pressure was increased to
atmospheric pressure. The imbibed polymerized intermediate was
crosslinked and semicrystalline at room temperature. The resulting
80 layer composite structure was divided into four sections by
cutting the composite with a razor blade at the corners of the
mandrel. The sections were removed from the mandrel and FEP release
layer, yielding four flat multilayer composite sheets 60 mm long,
30 mm wide, and about 0.3 mm thick. The composite sheets had a
density of about 1.1 g/cc.
[0290] The multilayer composite structure exhibited shape memory
behavior when exposed to a temperature between about 40.degree. C.
and about 55.degree. C. during the shape memory testing procedure
(non-porous) described herein.
Example 30
[0291] A thermally activated release mechanism was constructed from
a composite consisting of an ePTFE and the crosslinked polyester
composition described herein. The mechanism could be provided, for
example, at the distal end of a catheter to either release or
capture objects within a body.
[0292] The composite prepreg tape of Example 29 was cut with a
CO.sub.2 laser into 0.254 mm wide strips. The 0.254 mm prepreg
strips were wrapped circumferentially around a conical mandrel that
had been fashioned by chamfering the end of a brass rod. The
prepreg tape wrapped mandrel was placed in a vacuum oven at
120.degree. C. for 24 hours under reduced pressure. Upon cooling to
room temperature, the imbibed polymerized intermediate of the
composite object was not optically clear. As discussed above in
connection with Example 21, the imbibed polymerized intermediate
was crosslinked.
[0293] The composite was removed from the mandrel, but remained in
a conical shape in the absence of external forces or support from
the mandrel. A 0.127 mm diameter nitinol wire was inserted into the
center of the composite cone parallel to its longitudinal axis. The
wire and composite assembly was placed into a 60.degree. C. water
bath for several minutes, and the composite assembly was radially
compressed against the wire. While compressed, the composite
assembly and wire were placed into a 0.degree. C. temperature
chamber for several minutes. The sample then was removed from the
0.degree. C. temperature chamber, and the compressive forces
relieved. The composite kept its compressed shape (i.e., a cylinder
with the nitinol wire running through its long axis).
[0294] The ends of the nitinol wire were connected to a DC power
supply which was set to output 9 volts. The output was activated,
resistive losses in the wire resulted in a temperature increase in
the nitinol. This increase in temperature caused the composite to
assume a larger diameter permitting release of the nitinol wire.
The shape memory composite was substantially restored to its
original conical structure.
Example 31
[0295] Another composite embodiment exhibiting shape memory
properties was constructed by combining
poly(glycolide-co-trimethylenecarbonate) (PGA/TMC) nonwoven
material with the crosslinked polyester composition. The PGA/TMC
nonwoven web used to make the composite prepreg was made in
accordance with the teachings of Hayes in U.S. Pat. Nos. 6,165,217
and 6,309,423.
[0296] About 4 grams of the uncrosslinked semicrystalline
intermediate of Example 21 was sectioned into small granules with a
razor blade. A polyethylene release film was taped flat to a 152.4
mm.times.508 mm thin stainless steel sheet. A 101.6 mm.times.101.6
mm drawdown bar with a 0.2 mm gap was placed on the polyethylene
sheet, and the entire assembly was placed in an oven at 130.degree.
C. for about ten minutes. The assembly was removed from the oven
and the uncrosslinked semicrystalline intermediate granules were
placed in front of the drawdown bar. A heat gun was gently waved
over the uncrosslinked semicrystalline granules until they became a
molten mass. The drawdown bar then was pulled slowly along the
surface of the release liner to create a uniform molten thin film
of the amorphous uncrosslinked intermediate. The PGA/TMC nonwoven
web was placed onto the amorphous molten intermediate film. The
viscous intermediate wet and imbibed the PGA/TMC nonwoven web
resulting in a prepreg sheet of about 0.203 mm thickness.
[0297] After cooling to room temperature, a razor blade was used to
cut 8 rectangular prepreg strips from the prepreg sheet. Each sheet
had dimensions of 80 mm length.times.12.7 mm width. These prepreg
strips then were assembled into two multilayer stacks of four
layers per stack. The stacks were placed on a 203.2 mm.times.203.2
mm glass plate; the plate having been covered with 0.076 mm thick
PTFE film. Another PTFE film and glass plate were placed on top of
the stacks. A 678 gram stainless steel weight was placed on top of
the stack to compress the strips together.
[0298] The entire assembly was placed in a vacuum oven at
145.degree. C., and the pressure was reduced. These conditions were
maintained for 2.5 hours before the pressure was increased to
atmospheric and the temperature reduced. The stainless steel weight
was removed and pressure decreased. These conditions were
maintained for an additional 18.5 hours. Then pressure was again
increased to atmospheric and the top glass plate and PTFE film
removed. Pressure again was decreased with a vacuum pump. These
polymerization conditions maintained for an additional 1,440
minutes. The temperature was decreased to room temperature and
pressure was increased to atmospheric. In this way, two rectangular
shaped flat composite structures having dimensions of 80 mm
length.times.12.7 mm width.times.0.64 mm thickness were fabricated
from the prepreg sheet described above. The composite's density at
room temperature was about 1.2 g/cc.
[0299] The multilayer composite structure exhibited shape memory
behavior when exposed to a temperature between about 39.degree. C.
and about 46.degree. C. during the shape memory testing procedure
(non-porous) described herein.
Example 32
[0300] The following components were placed into a first 250 ml
glass beaker: 35.0 grams sebacic acid, 8.59 grams ethylene glycol,
and 3.19 grams glycerol (first sample). Into a second 250 ml glass
beaker were placed 35.0 grams sebacic acid, 7.52 grams ethylene
glycol, and 4.78 grams glycerol (second sample). The beakers and
their contents were placed in a vacuum oven set at 120.degree. C.
Two 100 mm diameter Petri dishes were treated with a Teflon.TM.
mold release agent and placed in the oven to preheat.
[0301] The initially heterogeneous solid-liquid mixture transformed
to a low viscosity fluid over the course of an hour. After about 1
hour, approximately 22.7 grams of each of the fluid mixtures was
poured into separate preheated Petri dishes. Each Petri dish and
sample was placed in a vacuum oven set at 130.degree. C. A vacuum
was applied and polymerization continued for about 4,320
minutes.
[0302] Then the oven power was turned off and the oven and product
cooled while maintaining reduced pressure. Pressure then was
increased to atmospheric and the product cooled to ambient
temperature. The samples were removed from the Petri dishes to
yield two disks. Titration reflected residual acidities of 1.450
meq. acid/gram and 0.6899 meq. acid/gram, respectively for sample 1
and sample 2.
[0303] A piece of sample 1 was cut into a rectangular strip 2.0 mm
wide and 30.0 mm long and 1.5 mm thick. Two similarly sized pieces
of sample 2 also were obtained. A composite was fashioned by
placing the two sample 2 strips on top of the sample 1 strip and
compressing in thickness using a heated Carver press (Carver, Inc.,
Wabash, Ind.) at 130.degree. C., under significant compressive
force for one hour. The compressed composite was cooled to room
temperature then removed from the press. The composite had a
nominal thickness of approximately 3 to 4 mm.
[0304] The composite was placed into a curved beam shape by placing
the sample and a tube in an oven at 60.degree. C. At this
temperature, the now-amorphous composite was fashioned to the
curvature of the tube and held in place with tape. The composite
then was placed into a freezer to cool the material to a
temperature of 0.degree. C.
[0305] From the cooled, curved sample, a 13.97 mm long sample was
cut. This sample was subjected to a stepped thermal program, which
raised the temperature at 5.degree. C./min from room temperature to
40.degree. C., held this temperature for 10 minutes, and then
raised the temperature to 70.degree. C., again at 5.degree. C./min.
The dimension change is shown in FIG. 20.
Example 33
[0306] The porous reaction product of Example 23 was first
compressed and set into a metastable state. A 6.45 cm.sup.2 piece
of semicrystalline foam of nominally 10 mm thickness was placed
into a 60.degree. C. water bath for several minutes. The now
amorphous foam was removed from the water bath and immediately
placed between two aluminum plates which were spaced apart by two
2.54 mm thick aluminum spacers. A clamp was used to hold the plates
together. The assembly was allowed to set overnight at room
temperature. The now semicrystalline metastable foam was removed
from between the plates and placed under vacuum for five minutes to
remove residual water.
[0307] The compressed metastable foam then was cut via a CO.sub.2
laser into 3.05 mm diameter cylinders. The heat generated by the
laser caused the temperature of the foam to rise which resulted in
shape recovery of the material. A 0.127 mm diameter nitinol wire
was pushed through the center of the recovered now amorphous foam
cylinder parallel to its long axis.
[0308] The wire and foam were placed into a 60.degree. C. water
bath for 5 minutes. Co-radial compression (with the cylinder and
the wire) was applied to the foam. The foam was placed into a
0.degree. C. temperature chamber for 10 minutes while compression
was maintained. The now semicrystalline metastable foam was
compressed tightly around the nitinol wire.
[0309] The wire-metastable foam assembly was inserted into the
in-vitro aneurysm model and fed into the simulated aneurysm. The
simulated aneurysm was a bubble of approximately 6.35 mm diameter
formed in a clear plastic tube, of approximately 70 mm in length
with an inner diameter of approximately 3.05 mm wall. The wire then
was connected to a DC power supply which was set to 9 volts. The
output voltage was applied, which caused resistive heating of the
nitinol wire. The heat generated resulted in shape recovery of the
foam composition, which in turn filled the simulated
aneurysm/bubble. The wire then was withdrawn.
Example 34
[0310] A vascular closure device model was constructed in the
following manner: A 101.6 mm.times.101.6 mm piece of nominally 7.62
mm thick foam of Example 22 was compressed in thickness using a
heated Carver press (Carver, Inc., Wabash, Ind.) at 65.degree. C.,
under one ton clamping force for about 3 hours. The compressed foam
was cooled to room temperature then removed from the press. Once
removed, the foam had a nominal thickness of approximately 1.143
mm. The compressed foam then was cooled below room temperature with
compressed air. The foam then was die cut to form a compressed plug
using a 2.388 mm inner diameter hypodermic tube (available from
Small Parts, Miami Lakes, Fla.) that was taper ground to form sharp
leading edge. The compressed plug was removed from the end of the
hypodermic cutting tube and again cooled below room
temperature.
[0311] An intraluminal delivery device for the closure device
included an expanding braided shaft having a central lumen. An
actuating wire was disposed within the lumen. The actuating wire
was attached to the braided shaft at the distal end. The braided
shaft is substantially covered by a polymeric material which
prevented radial expansion, elongation or shortening of the braid.
Near the distal end a section of the braided shaft was not covered
and unrestrained. This uncovered portion separated the polymeric
cover into a distal portion and a proximal portion. An overtube
covered the proximal portion of the polymeric cover. When the
overtube and proximal end of the device was held and the actuating
wire was pulled proximally, the distal end of the device moved
proximally and the braided shaft expanded within the unrestrained
portion to form a disk like projection extending perpendicularly to
the axis of the delivery device. The compressed plug was threaded
over the proximal polymeric cover and pushed distally by the over
tube. The actuating wire then was pushed distally to retract the
braid.
[0312] A simulated vascular system to be repaired was constructed
of a silicone tube, which simulated an artery. The tube was placed
in an outer tube filled with gelatin to simulate the surrounding
tissue. An introducer was inserted into the silicone tube.
Insertion of the introducer created the simulated wound to be
closed.
[0313] The vascular closure device was delivered to the repair site
via the introducer. The braid was positioned beyond the injury site
before the braid was expanded. The closure device was pushed
distally against the expanded braid using the overtube. With the
closure device locked in position between the overtube and the
braid, the assembly was withdrawn until the braid contacted the
inner wall of the simulated artery. Warm saline was provided via
the introducer to activate the shape memory property of the closure
device. The introducer then was withdrawn. The unrestricted closure
device then expanded to provide a patch at the simulated injury
site. The polymer foam was disposed between the outer wall of the
simulated artery and the simulated surrounding tissue. After
placing the device, the braid was retracted by pushing the
actuating wire distally. After retraction, the entire delivery
device was withdrawn. The closure device was held in place by the
over tube, which was ultimately removed.
Example 35
[0314] A 175 mm.times.8 mm ID, 24 end braid of 0.127 mm nitinol
wire (Medical Murray, North Barrington, Ill.) was placed on an 8 mm
OD SS tube (McMaster Carr, New Brunswick, N.J.). A 100 mm width
section of composite prepreg of Example 29 was continuously wrapped
in the machine direction around the nitinol braid and tube 6 to 8
full revolutions. This construct then was heated to 160.degree. C.
under vacuum for 10 hours and then cooled with liquid CO.sub.2.
When the temperature of the resulting assembly reached room
temperature, the mandrel was removed.
[0315] The assembly then was heated in an oven at 50.degree. C. for
10 minutes. Upon removal from the oven, the assembly was
immediately pulled in axial tension by grabbing the two opposing
ends of the nitinol braid and stretching, thereby reducing the
diameter, and increasing the length of the composite-nitinol braid.
Then, the assembly was cooled using liquid CO.sub.2. Cooling fixed
the braid and composite in an elongated metastable state. The
assembly retained the metastable state at room temperature. Upon
heating the assembly to 45.degree. C., the assembly shortened in
length and expanded in diameter, thereby substantially recovering
its original dimensions. This assembly operated in this manner
multiple times.
Example 36
[0316] The hemostatic properties of the foam were demonstrated in a
porcine liver laceration model. Several foams were selected for
testing. The materials differed in pore size and handling
properties which are detailed in Table 2, below. The samples used
were in the form of cylinders approximately 15 mm in diameter and
between 6 mm and 10 mm in length. Cotton gauze was used as a
comparison.
TABLE-US-00002 TABLE 2 Shape Stored Material Pore Size State at
22.degree. C. In Sample Hemostasis Cotton Gauze N/A N/A N/A -
Example 20 Large Semicrystalline No + Example 21 Large
Semicrystalline No +/- Example 22 Small Semicrystalline No ++
Example 23 Large Semicrystalline Yes ++ Example 24 Large Amorphous
No +/- no hemostasis within 5 minutes with compression; +/-
hemostasis within 3 minutes with compression; + homeostasis within
1 minute with compression; ++ hemostasis within 5 seconds with no
compression
[0317] One untreated Yucatan swine with normal average clotting
time was used in the study. A midline incision was used to expose
the liver. A 13 mm diameter trephine was used to core holes
approximately 1 cm deep in the liver. The wounds bled profusely for
5 seconds after which the sample materials were inserted into the
wound. No external pressure was applied initially. The time to
cessation of bleeding through the wound was measured. After five
minutes, the material was removed from the wound, placed in 10%
neutral buffered formalin, and processed for histological
analysis.
[0318] All foam materials were easy to handle and apply to the
wound, and all filled with blood and produced hemostasis within 3
minutes. The foam of Example 22, which had small pores, and the
foam of Example 23 (which had stored shape) produced hemostasis
within 5 seconds after application to the wound without applying
compression to the wound. The foam of Example 20 produced
hemostasis within one minute after applying compression. Slow
bleeding was observed surrounding Examples 21 and 24 after one
minute of compression, but hemostasis was complete after two
minutes without further compression.
[0319] Histologic evaluation of the retrieved samples was
conducted. The interstices of Example 22 foam were filled with
fewer erythrocytes and a greater proportion of proteinaceous fluid
then the other examples. In those specimens the microstructure
contained pools of essentially intact blood. There was also no
evidence of frank toxicity.
Test Methods
Shape Memory:
[0320] The shape memory behavior of porous products may be probed
as follows: right circular cylinders are extracted from the dried
foam product at 22.degree. C. using a cork borer having an internal
diameter of 15.4 mm. The initial or default state length and
diameter dimensions of each cylinder are measured to the nearest
0.01 mm and respectively designated, L.sub.0 and D.sub.0. The
initial or default state cylinder volume, V.sub.0, is calculated as
follows:
V o = 1 4 .pi. D o 2 L o . ##EQU00003##
[0321] Next, a metastable state is created by deforming the right
circular cylinder in uniaxial compression while the polymer foam is
in its amorphous state to a linear compressive strain, .epsilon.,
in the range 0.3.ltoreq..epsilon..ltoreq.0.5. After deformation,
the temperature is decreased to 0.degree. C., while holding
constant the compressive strain. The temperature and compressive
strain are maintained for 25 hours to 40 hours before increasing
temperature to 22.degree. C. After about one hour, the external
compressive force is decreased to zero. The deformed or metastable
state dimensions of the cylinder are measured to the nearest 0.01
mm and respectively designated L.sub.d and D.sub.d. The metastable
state volume, V.sub.d, of each cylinder may be calculated and
designated as follows:
V d = 1 4 .pi. D d 2 L d . ##EQU00004##
[0322] The metastable state linear compressive strain,
.epsilon..sub.L,d, and volumetric compressive strain,
.epsilon..sub.V,d, may be calculated as follows:
L , d = ( L d L o ) L o ##EQU00005## V , d = ( V d V o ) V o
##EQU00005.2##
[0323] To determine if the samples are dimensionally stable, the
metastable state cylinders are stored at 22.degree. C. in the
absence of an external force field for eight days.
[0324] To determine if the metastable state foam cylinders
substantially recover their original or default state dimensions
via a thermal stimulus, each is placed in a warm aqueous solution
at a temperature of 30.degree. C. to 100.degree. C. The metastable
state foam cylinders then are placed into the solution for one
hour. After one hour, the dimensions of the cylinders are measured
to the nearest 0.01 mm and respectively designated, L.sub.r and
D.sub.r. The volume of the shape recovered foam cylinders may be
calculated as follows:
V r = 1 4 .pi. D r 2 L r ##EQU00006##
[0325] The measurements are made while the foam is water saturated.
Next, the saturated foam cylinders are dried in a vacuum oven at
30.degree. C. to 100.degree. C. to constant weight. The linear
dimensions and volume of the shape recovered foam cylinders are
compared to that of the original or default state cylinders. Shape
memory behavior is demonstrated if the sample recovers at least 50%
of its original dimension.
[0326] The shape memory behavior of non-porous products may be
evaluated in a three step shape recovery experiment. First, a right
rectangular prism of the sample is deformed by bending the sample
around a brass pipe at a temperature at which the sample is in an
amorphous state. Second, the sample is cooled to room temperature,
and the deforming force is removed to determine if the bent shape
is maintained. Third, the sample is heated to determine if it tends
to revert to its shape before deformation. The procedure is
described in more detail below.
[0327] At 22.degree. C., strips of adhesive tape (150 mm.times.20
mm) are placed with the adhesive side up on a flat benchtop. A
right rectangular prism (35 mm.times.5 mm.times.2 mm) of the sample
to be tested is placed onto the tape such that it has a long axis
oriented parallel to the long axis of the tape and about 50 mm of
tape projected from one end of the sample. The sample is secured to
the tape.
[0328] One end of the exposed tape is attached to a brass thin
walled pipe having an outer diameter of 20.7 mm so that the long
axis of the prism and tape is orthogonal to the pipe axis. The pipe
and sample or samples to be tested are placed in an oven at
90.degree. C. for 30 minutes prior to deforming them. Each sample
then is deformed by wrapping the tape around the pipe and securing
the free end of the tape to the pipe. The entire assembly is cooled
at 22.degree. C.
[0329] The deforming force is removed by removing the tape from the
sample and pipe assembly. Samples that do not maintain their shape
(i.e., do not maintain a metastable state) are determined not to
have shape memory. Samples that do maintain their deformed shape
(i.e., do maintain a metastable state) may be further evaluated to
determine the stability of the deformed shape. Such samples are
stored in deformed or metastable state.
[0330] The samples then are tested to determine if the original
state would be substantially recovered upon applying an activating
stimulus. Approximately 10 mm long samples of the deformed prisms
are cut from the sample. These 10 mm long samples are placed across
quartz knife edges spaced 5 mm apart. The samples are heated from
20.degree. C. at 1.degree. C./min. Samples that substantially
recover their original state at a temperature of less than about
100.degree. C. are considered to have shape memory properties.
Samples substantially recovering their original state between about
30.degree. C. and 60.degree. C. were considered to have particular
applicability in human medical applications.
Modulus
[0331] Elastic moduli, such as Young's modulus, can be measured
with a dynamic mechanical analyzer (DMA) at strains of less than 1%
as a function of temperature. The temperature ramp rate is
1.degree. C./min. The frequency is 1 Hz.
Cytotoxicity Testing:
[0332] Minimum Essential Media (MEM) may be used to evaluate the
presence of cytotoxic extractables and their effect on living
mammalian cells. A polymer sample is extracted with the extraction
media at 37.degree. C..+-.1.degree. C. for 24 to 30 hours. L929
mouse fibroblast cells are exposed to the test extract at
37.degree. C. for 72 hours. After staining, cells are examined with
the aid of a light microscope. A visual assessment of the
biological response considers the state of health of a monolayer of
the cells. Cytotoxicity is scored on a scale of 0 (negative
response) to 4 (more than 75% of cells morphologically changed).
Results of 2 to 4 are cytotoxic.
[0333] Polymer samples are not rinsed prior to extraction. Samples
are extracted using 1 gram of sample to 5 ml MEM with 5% newborn
calf serum, 292 mg/l L-glutamine in distilled deionized water, 1.2
g/l sodium bicarbonate, 3.6 g/l HEPES and 100 .mu.g/ml
gentamycin.
[0334] Natural rubber latex is used as a positive control and it is
extracted in the same manner as the test samples. A negative
control or blank extraction is also included.
[0335] Sufficient quantity of L929 mouse fibroblast cells are grown
in wells for 24 to 96 hours. Cells are trypsinized and cell
suspensions are prepared. Each cell suspension is diluted with MEM
Growth Media to a concentration of 1-3.times.10.sup.5 cells/ml. The
diluted cell suspension is gently mixed and used to seed 35 mm test
wells. The cells are incubated at 37.degree. C..+-.1.degree. C. in
an atmosphere of 5%.+-.1% CO.sub.2 and a relative humidity of
greater than about 90%. Incubation continues until a confluent
monolayer forms (.gtoreq.80% confluent).
[0336] The MEM Growth Media is aspirated from the cells in the test
wells and is replaced with the same volume of test sample extract.
Test wells then are incubated under the conditions specified above
for an additional 72.+-.3 hours. After incubation, sufficient
dilute neutral red in sterile phosphate buffered saline is added to
the cells in each well to yield a final dye concentration of about
50 .mu.g/ml. These preparations are then returned to the incubator
under the specified conditions for 1-2 hours. After this final
incubation, wells are stained red. Viable cells are stained red.
However, nonviable cells are not stained, rather these cells remain
clear. Cells are examined by optical microscopy at a magnification
of 100.times. to 400.times., and cytotoxicity is rated on a scale
of 0 to 4 using the following cytotoxicity scoring table. All
positive controls are toxic at a titer of about 1.4 to about 1.64
dilution. All negative controls have a score of zero.
TABLE-US-00003 Cytotoxicity Scoring Table Microscopic Observations
Following Addition Score Of Neutral Red And Incubation As Outlined
Above 0 Negative response, cell morphology and density are like
negative controls. 1 Similar to control but .ltoreq.25% of cells
are granular, swollen or crenated. 2 >25% of cells are granular,
swollen or crenated, and/or 25-49% are dead, lysed or sloughed. 3
50% to 74% of the cells are dead, lysed or sloughed cells. 4 75% to
100% of the cells are dead, lysed or sloughed cells.
[0337] Scores of 0 or 1 are considered nontoxic. Scores of 2 to 4
are considered toxic.
[0338] While particular embodiments of the present invention(s)
have been illustrated and described herein, the present
invention(s) should not be limited to such illustrations and
descriptions. It should be apparent that changes and modifications
may be incorporated and embodied as part of the present
invention(s) within the scope of the following claims.
* * * * *