Contraceptive medical device

Abstract

To provide a biocompatible, non-invasive, cost-effective, reversible and convenient contraceptive medical device and method for local administration of one or more active agents.SOLUTION: Disclosed herein is a contraceptive medical device comprising at least a polymeric ring, a porous barrier material, and an injection molded guide, wherein the guide may be symmetrical and / or have one or more planar surfaces, and wherein the device may optionally administer at least one active agent.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 62 / 934,090, filed November 12, 2019, and U.S. Provisional Patent Application No. 63 / 019,884, filed May 4, 2020, each of which is incorporated herein by reference in its entirety for all purposes. The present disclosure relates to contraceptive medical devices, and in particular to intravaginal medical devices that include a ring, an injection molded guide, and a barrier material. [Background technology]

[0002] Effective contraceptive medical devices or medicines are desired by reproductive populations worldwide. The success of a contraceptive medical device depends not only on the effectiveness of the contraceptive method, but also on the user's preference, the reversibility of the contraceptive medical device or medicine; the convenience for the user, and the user's compliance. The need for effective contraceptive methods (including medicines or medical devices) continues to be a vital need. It is estimated that 50% of pregnancies are unplanned and that a woman dies every two minutes worldwide from pregnancy and childbirth-related problems. Although widely used, hormone-based contraceptives are currently known to act systemically on the user and are contraindicated in individuals with various cardiovascular conditions. It would therefore be desirable to provide new and improved contraceptive medical devices that provide local administration of the active agent and that are easier to use than conventional devices and methods. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2009 / 048594 [Patent Document 2] US Patent Application Publication No. 2010 / 0062039 [Patent Document 3] Special Publication No. 07-028888 Summary of the Invention [Problem to be solved by the invention]

[0004] Therefore, there is a need to provide a biocompatible, non-invasive, cost-effective, reversible, and convenient contraceptive medical device for the local administration of one or more active agents to prevent pregnancy. The present disclosure provides contraceptive medical devices and related equipment and methods to meet this need. (Summary of the Invention) [Means for solving the problem]

[0005] Briefly, the present disclosure discloses contraceptive medical devices, components thereof, methods of manufacturing and using the contraceptive medical devices and components thereof, and compositions contained therein. In one aspect, the present disclosure provides a contraceptive device comprising a porous barrier material and an injection-molded guide, the injection-molded guide optionally secured to the barrier material, and the injection-molded guide and the porous barrier material may each be at least partially encased in a polymer ring surrounding the porous barrier material, in one embodiment, the injection-molded guide being completely embedded in the polymer ring and the porous barrier material being partially embedded in the polymer ring. Thus, in one aspect, the present disclosure provides a contraceptive device comprising a porous barrier material, an injection-molded guide, and a polymer ring, the injection-molded guide being entirely embedded in the polymer ring and the porous barrier material being partially embedded in the polymer ring. The injection-molded guide may be symmetrical so that two or more pins can engage the injection-molded guide evenly during the injection molding process. The injection-molded guide may have multiple planar surfaces, for example, 3, 4, 5, 6, 7, or 8 planar surfaces. The injection-molded guide is at least partially embedded within a polymer ring structure, and in one embodiment, the injection-molded guide is embedded within the polymer ring structure. For example, the present disclosure provides a contraceptive device including a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide has multiple planar surfaces, and each of the injection-molded guide and the porous barrier material is at least partially embedded within the polymer ring, and optionally, the injection-molded guide is completely embedded within the polymer ring and the porous barrier material is partially embedded within the polymer ring.As another example, the present disclosure provides a contraceptive device including a polymer ring, a porous barrier material, and an injection-molded guide, the injection-molded guide having a symmetrical appearance when viewed in cross-section such that the left side of the cross-section is a mirror image of the right side of the cross-section, the injection-molded guide and the porous barrier material each being at least partially embedded within the polymer ring, and optionally, the injection-molded guide being completely embedded within the polymer ring and the porous barrier material being partially embedded within the polymer ring.

[0006] Optionally, the contraceptive device may be further characterized by the features disclosed herein, for example, by one or more of the following features: the barrier material is a mesh; the barrier material is a fibrous mesh; the barrier material is fibrous; the barrier material is circular; the barrier material is substantially circular; the barrier material has a diameter, for example, from about 40 mm to about 60 mm, for example, from about 45 mm to about 53 mm; the injection molded guide is non-fibrous; the injection molded guide has a melting point above the temperature used for injection molding, for example, a melting point above 120°C; the injection molded guide has a uniform cross-section all around the periphery of the injection molded guide; the injection molded guide has a corner formed by two planar surfaces intersecting at an angle (optionally an angle of 45 degrees to 135 degrees, for example, an angle of 85 degrees to 95 degrees, for example, an angle of 90 degrees); the injection molded guide has a polymer coating; The support ring is uncoated; the injection-molded guide does not contain a sizing polymer; the injection-molded guide has a single composition throughout the support ring; the injection-molded guide is biodegradable; the injection-molded guide is along the edge of the barrier material; the injection-molded guide is adjacent to the edge of the barrier material; the injection-molded guide extends into the porous barrier material; the injection-molded guide is 3D printed on the barrier material; the injection-molded guide is injection molded onto the barrier material; the ring structure comprises an elastomeric polymer, e.g., siloxane; the contraceptive device includes a bioactive agent present within the polymer ring structure; the contraceptive device comprises a ferrous compound present within the polymer ring structure; the contraceptive device comprises ferrous gluconate or a hydrate thereof present within the polymer ring structure; the contraceptive device comprises a ferrous compound and ascorbic acid, each present within the polymer ring structure. These and other features and options of the contraceptive devices of the present disclosure are described herein.

[0007] In one aspect, the present disclosure provides a kit comprising a contraceptive device described herein, e.g., a kit comprising the contraceptive device described above, wherein the kit further comprises at least one of a lubricant, a spermicidal gel, a spermicidal film, a contraceptive gel, and an applicator.

[0008] In one aspect, the present disclosure provides a construct that can be used to form the contraceptive device of the present disclosure. The construct includes a porous barrier material secured to an injection-molded guide, the injection-molded guide having a plurality of planar surfaces. Optionally, the construct may further be characterized by one or more of the features described herein, such as the following: the barrier material is a mesh; the barrier material is a fibrous mesh; the barrier material is fibrous; the barrier material is circular; the barrier material is substantially circular; the barrier material has a diameter of about 40 mm to about 60 mm, e.g., about 45 mm to about 53 mm; the injection-molded guide is non-fibrous; the injection-molded guide has a melting point above the temperature used for injection molding, e.g., a melting point greater than 120°C; the injection-molded guide has a uniform cross-section throughout its periphery; the injection-molded guide is formed at an angle. The injection molded guide has a corner formed by two planar surfaces intersecting at an angle (e.g., about 45 degrees to about 135 degrees, such as 85 to 95 degrees, e.g., a 90 degree angle); the injection molded guide is uncoated; the injection molded guide does not contain a sizing polymer; the injection molded guide has a single composition; the injection molded guide is biodegradable; the injection molded guide is along the edge of the barrier material; the injection molded guide is in close proximity to the edge of the barrier material; the injection molded guide extends into the porous barrier material; the injection molded guide is 3D printed on the barrier material; or the injection molded guide is injection molded onto the barrier material.

[0009] In one aspect, the present disclosure provides methods for forming the disclosed constructs and contraceptive devices. For example, the present disclosure provides a method for forming a contraceptive device, the method including the steps of: (a) providing a construct comprising a porous barrier material secured to an injection-molded guide, the injection-molded guide comprising a plurality of planar surfaces; (b) placing the construct into a die; (c) adjusting the position of at least one pin in the die so that the at least one pin contacts a surface of the injection-molded guide; and (d) injecting molten polymer into the die to form a ring structure that embeds the injection-molded guide. As another example, the present disclosure provides a method for forming a construct, the method including 3D printing an injection-molded guide on a porous barrier material. As yet another example, the present disclosure provides a method for forming a construct, the method including forming an injection-molded guide, optionally by an injection-molding process; and then securing the injection-molded guide on the porous barrier material. As a further example, the present disclosure includes a method of forming a contraceptive device, the method including: (a) providing a construct comprising a porous barrier material secured to an injection molding guide, the injection molding guide being symmetrical and comprising a plurality of planar surfaces; (b) placing the construct into a die (optionally a heated die); (c) adjusting the position of at least one pin in the die so that the at least one pin contacts a surface of the injection molding guide; (d) injecting a two-part thermosetting polymer mixture into the die to form a polymer ring, wherein the injection molding guide and the porous barrier material are each at least partially embedded within the polymer ring; curing the two-part thermosetting polymer mixture in the mold such that the two-part thermosetting polymer mixture changes from a liquid state to a solid state; and (f) removing the contraceptive device from the die.

[0010] The present disclosure provides various aspects and embodiments of contraceptive devices, constructs useful for forming contraceptive devices, and methods related to the formation and use of such contraceptive devices, and these various aspects and embodiments may be combined to describe the contraceptive devices, constructs, and related methods of the present disclosure. For example, in one aspect, the contraceptive device comprises a polymeric ring structure, an injection-molded guide, and a porous barrier material, wherein the polymer of the polymeric ring structure comprises silicone, and the polymeric ring structure further comprises particles of ferrous gluconate, ascorbic acid, glycine, and poly(glycolic acid). The device may further be described as follows: embedded within the silicone ring structure is an injection-molded guide comprising a lactide / trimethylene carbonate polymer, wherein lactide comprises greater than about 70% (w / w), e.g., 80% (w / w), of the polymer, the guide having a melting point above the temperature used for injection molding. The device may further be described as follows: the injection-molded guide has at least one planar surface. The device may further be described as comprising a porous barrier material partially embedded within a polymer ring structure, the barrier material completely traversing the inner diameter of the ring. The device may further be described as comprising a fibrous multifilament mesh formed at least in part from a lactide / trimethylene carbonate polymer, the lactide comprising greater than 70% (w / w) or greater than 80% (w / w) of the polymer. The contraceptive device may further be described as having an outer diameter of about 40 mm to about 60 mm, e.g., about 45 mm to about 53 mm. The device may further be described as being free from contamination with Pseudomonas aeruginosa, Staphylococcus aureus, or Candida albicans, and optionally having a bacterial endotoxin level of 20 EU or less. The device can be further described in terms of its performance characteristics, for example, in one aspect, the contraceptive device releases ferrous ions for at least 35 days when placed in simulated vaginal fluid. In one aspect, the present disclosure provides a kit containing a contraceptive device having the aspects and embodiments described herein, in which the contraceptive device is packaged and, optionally, includes instructions for use.

[0011] The present disclosure provides the following exemplary, non-exclusive embodiments, which are numbered for convenience: 1) A contraceptive device comprising a polymer ring, a porous barrier material, and an injection molded guide, wherein each of the injection molded guide and the porous barrier material is at least partially embedded within the polymer ring. 2) The contraceptive device of embodiment 1, wherein the barrier material is a mesh. 3) The contraceptive device of embodiment 1, wherein the barrier material is fibrous. 4) A contraceptive device according to any one of embodiments 1 to 3, wherein the barrier material is circular or substantially circular. 5) The contraceptive device according to any one of embodiments 1 to 4, wherein the barrier material has a diameter of about 40 mm to about 60 mm, for example, about 45 mm to about 53 mm. 6) A contraceptive device according to any one of embodiments 1 to 5, wherein the injection-molded guide is symmetrical. 7) A contraceptive device according to any one of embodiments 1 to 6, wherein the injection molded guide comprises a plurality of planar surfaces. 8) A contraceptive device as described in embodiments 1 to 7, wherein the injection-molded guide comprises a plurality of planar surfaces and has a corner formed by the intersection of two planar surfaces, and optionally the injection-molded guide has a corner formed by two planar surfaces that intersect at an angle, the angle being between 45 degrees and 135 degrees, for example, a 90 degree angle. 9) A contraceptive device according to any one of embodiments 1 to 8, wherein the injection-molded guide is at least one of non-fibrous and non-porous. 10) A contraceptive device according to any one of embodiments 1 to 9, wherein the injection-molded guide is completely embedded within the polymer ring and the porous barrier material is partially embedded within the polymer ring. 11) A contraceptive device according to any one of the preceding embodiments, wherein the injection-molded guide is uncoated and / or does not contain a sizing polymer. 12) A contraceptive device according to any one of the preceding embodiments, wherein the injection-molded guide is fixed to the porous barrier material. 13) A contraceptive device according to any one of embodiments 1 to 12, wherein the injection-molded guide has a composition that is constant throughout the injection-molded guide. 14) A contraceptive device according to any one of embodiments 1 to 13, wherein the injection-molded guide is biodegradable. 15) A contraceptive device according to any one of the preceding embodiments, wherein the injection-molded guide is located along the edge of the porous barrier material. 16) A contraceptive device according to any one of the preceding embodiments, wherein the injection-molded guide is adjacent to the edge of the porous barrier material. 17) A contraceptive device according to any one of the preceding embodiments, wherein the injection-molded guide extends into the porous barrier material. 18) A contraceptive device according to any one of embodiments 1 to 17, wherein the injection molded guide is 3D printed onto the porous barrier material. 19) A contraceptive device according to any one of the preceding embodiments, wherein the injection-molded guide is injection-molded onto the porous barrier material. 20) A contraceptive device according to any one of embodiments 1 to 19, wherein the polymer ring comprises an elastic polymer. 21) A contraceptive device according to any one of embodiments 1 to 20, wherein the polymer ring surrounds the porous barrier material. 22) The contraceptive device of embodiments 1-21, further comprising a bioactive agent present within the polymer ring. 23) The contraceptive device of embodiments 1-21, further comprising a ferrous compound present within the polymer ring. 24) A contraceptive device according to any one of embodiments 1 to 21, further comprising ferrous gluconate or a hydrate thereof present within the polymer ring, and optionally further comprising ascorbic acid present within the polymer ring. 25) A kit comprising the contraceptive device described in embodiments 1 to 24, further comprising at least one of a lubricant, a spermicidal gel, a spermicidal film, a contraceptive gel, and an applicator. 26) A construct for forming a contraceptive device, such as the contraceptive device of any of embodiments 1 to 24, comprising a porous barrier material fixed to an injection molding guide. 27) The construct of embodiment 26, wherein the barrier material is a mesh. 28) A construct according to embodiments 26-27, wherein the barrier material is fibrous. 29) The construct of any one of embodiments 26 to 28, wherein the barrier material is circular or substantially circular. 30) The construct of embodiments 26 to 29, wherein the barrier material has a diameter of about 40 mm to about 60 mm, for example, about 45 mm to about 53 mm. 31) A construction according to any one of embodiments 26 to 30, wherein the injection molding guide is symmetrical. 32) A construction according to any one of embodiments 26 to 31, wherein the injection molded guide has a uniform cross section all around the periphery of the injection molded guide. 33) A construction according to any one of embodiments 26 to 32, wherein the injection molding guide comprises a plurality of planar surfaces. 34) A construction according to any one of embodiments 26 to 33, wherein the injection molding guide has a corner formed by the intersection of two planar surfaces, and optionally the injection molding guide has a corner formed by two planar surfaces that intersect at an angle, the angle being between about 45 degrees and about 135 degrees, e.g., about 90 degrees. 35) A construction according to any one of embodiments 26 to 34, wherein the injection-molded guide is non-fibrous and optionally non-porous. 36) The construction of any one of embodiments 26 to 35, wherein the injection molded guide has a melting point greater than 120°C. 37) The construction of any one of embodiments 26 to 36, wherein the injection molded guide is uncoated. 38) The construction of any one of embodiments 26-37, wherein the injection molded guide does not contain a sizing polymer. 39) The construction of any one of embodiments 26-38, wherein the injection molded guide has a single composition at each location of the injection molded guide. 40) A construct according to any one of embodiments 26 to 39, wherein the injection-molded guide is biodegradable. 41) A construction according to any one of embodiments 26 to 40, wherein the injection molding guide is along the edge of the porous barrier material. 42) A construction according to any one of embodiments 26 to 40, wherein the injection molding guide is located adjacent to the edge of the barrier material. 43) A construction according to any one of embodiments 26 to 42, wherein the injection molded guide extends into the porous barrier material. 44) A construct according to any one of embodiments 26 to 43, wherein the injection molded guide is 3D printed on the porous barrier material. 45) The construction of any one of embodiments 26-43, wherein the injection molded guide is injection molded onto the porous barrier material. 46) A method of forming a contraceptive device, such as the contraceptive device of any one of embodiments 1-24, comprising: a. providing a construct comprising a porous barrier material secured to an injection molding guide; b. placing the construct in a die; c. adjusting the position of at least one pin within the die so that the at least one pin contacts a surface of the injection molding guide; and d. injecting molten polymer into the die to form a polymer ring, wherein each of the injection molding guide and the porous barrier material is at least partially embedded within the polymer ring; A method comprising: 47) The method of embodiment 46, wherein the construct is provided by a method comprising 3D printing an injection molded guide onto the porous barrier material. 48) The construct is a. forming an injection molded guide by an injection molding process; b. securing an injection molding guide over the porous barrier material 47. The method of embodiment 46, provided by a method comprising: 49) A method of forming a contraceptive device, such as the contraceptive device of any one of embodiments 1-24, comprising: a. providing a construct comprising a porous barrier material secured to an injection molding guide; b. placing the construct into a heated die; c. adjusting the position of at least one pin within the die so that the at least one pin contacts a surface of the injection molding guide; d. injecting a mixture of two-part thermosetting polymer into the die to form a polymer ring, wherein each of the injection molding guide and the porous barrier material is at least partially embedded within the polymer ring; e. curing the two-part thermosetting polymer mixture in the mold so that the two-part thermosetting polymer mixture changes from a liquid state to a solid state; and f. Removing the formed product from the die; A method comprising: 50) The method of embodiment 49, wherein the construct is provided by a method comprising 3D printing an injection molded guide onto the porous barrier material.

[0012] The above and additional features of the present specification, as well as the manner in which they can be obtained, will become apparent. The present invention will be best understood by reference to the following more detailed description. All references disclosed herein are incorporated by reference in their entirety, as if each were individually incorporated.

[0013] This Summary is provided to introduce certain concepts in a simplified form that are more fully described below in the Detailed Description. Unless otherwise specified, this Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to limit the scope of the claimed subject matter. Details of one or more embodiments and aspects are set forth below. Features illustrated or described with respect to one exemplary embodiment or aspect may be combined with features of other embodiments or aspects. Thus, any of the various embodiments or aspects described herein can be combined to provide further embodiments of the present disclosure. Features of the embodiments and aspects can be modified, if necessary, to employ concepts from the various patents, applications, and publications identified herein and to provide further embodiments. Other features, objects, and advantages will become apparent from the description, drawings, and claims. Exemplary features of the present disclosure, its nature, and various advantages will become apparent from the accompanying drawings and the following detailed description of various embodiments. Non-limiting and non-exhaustive embodiments are described with reference to the accompanying drawings, in which like labels or reference numerals refer to like parts throughout the various views unless otherwise specified. The sizes and relative positions of elements in the figures are not necessarily drawn to scale. For example, the shapes of various elements have been selected, enlarged, and positioned to improve the readability of the figures. The particular shapes of the depicted elements have been selected for easy recognition of the figures. One or more embodiments are described below with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is a plan view of an exemplary contraceptive medical device disclosed herein, showing the injection molded guide (1), porous barrier material (2), and ring structure (3). [Figure 2] FIG. 2 is a schematic side view of a portion of an exemplary contraceptive medical device disclosed herein, more specifically, the portion identified at "A" in FIG. 1, showing the injection molded guide (1), porous barrier material (2), and ring structure (3). [Figure 3] Figures 3A, 3B, 3C, 3D, 3E, 3F, 3G, 3H and 3I each show a cross-section of a schematic portion of an exemplary injection molded guide (1) provided on a porous barrier material (2) of an exemplary construction disclosed herein. [Figure 4] 1 shows a schematic of an exemplary injection molded guide (1) provided on a porous barrier material (2) of an exemplary contraceptive medical device disclosed herein. [Figure 5] 5A and 5B each show a schematic of an exemplary injection molded guide (1) disposed on a porous barrier material (2) of an exemplary contraceptive medical device disclosed herein. [Figure 6]6A, 6B, and 6C show schematics of an exemplary construction, with FIG. 6A showing a plan view of the construction, FIG. 6B showing a full cross-sectional view of the construction of FIG. 6A taken along line B in FIG. 6A, and FIG. 6C showing a partial cross-sectional view of the construction of FIG. 6A, particularly the portion of the cross-section included within the area indicated by C in FIG. 6B. DETAILED DESCRIPTION OF THE INVENTION

[0015] Disclosed herein are contraceptive medical devices (also referred to as contraceptive devices), methods for making and using such contraceptive devices, and constructs useful for making such contraceptive devices. In one aspect, the present disclosure provides a contraceptive device including a barrier material, an injection-molded guide, and a ring structure. For example, the present disclosure provides a contraceptive device including a polymer ring, a porous barrier material, and an injection-molded guide, each of which is at least partially embedded within the polymer ring. The barrier material can delay the passage of sperm through the barrier material but not prevent vaginal fluid from passing through the barrier material. In one aspect, the barrier material is porous, or at least partially porous, with a pore size that delays the passage of sperm through the barrier material but allows vaginal fluid to pass through the porous barrier material. The polymer ring facilitates the contraceptive device maintaining a fixed position in vivo, particularly within the vaginal canal. The injection-molded guide facilitates efficient manufacturing of the contraceptive device. Optionally, the contraceptive device further comprises a bioactive agent, and optionally further comprises one or more of an excipient, a pH adjuster, an antioxidant, a preservative, and a release modifier that modulates release of the bioactive agent. Optionally, the bioactive agent is a component of a composition, the composition functions to reduce the likelihood of sperm entering the cervix. In one aspect, the present disclosure provides a method of manufacturing a contraceptive device comprising a barrier material, an injection molded guide, and a polymer ring, the method comprising forming the polymer ring by injection molding a polymer ring portion of the contraceptive device, the injection molding utilizing the injection molded guide. In another aspect, the present disclosure provides a method of achieving contraception comprising inserting a contraceptive device into the vaginal canal.

[0016] In another aspect, the present disclosure provides a construct comprising a barrier material and an injection molding guide, which can serve as a precursor to or be part of a contraceptive device. In another aspect, the present disclosure provides a method for preparing the construct, and also provides a method for preparing a contraceptive device using the construct. In one aspect, the construct is placed into a cavity (optionally called a mold or die) in an injection molding machine, where two or more pins on the injection molding machine engage with the injection molding guide of the construct, which serve to position and / or secure the construct in a desired location within the mold during injection molding of the polymer ring. In one aspect, the injection molding guide has a symmetrical shape, such that the pins engage the injection molding guide uniformly, regardless of where the construct was originally located within the chamber. In other words, when the multiple pins extend uniformly into the mold to engage the injection mold guide, each of the multiple pins engages the injection mold guide equally, for example, one of the multiple pins does not have to extend further into the mold to engage the injection mold guide than any other of the multiple engagement pins. This symmetry of the injection mold guide facilitates efficient manufacturing of the contraceptive device of the present disclosure.

[0017] Figure 1 shows a schematic plan view of an exemplary contraceptive device of the present disclosure, comprising an injection-molded guide (1), a porous barrier material (2), and a ring structure (3), sometimes referred to herein as a polymer ring. While the injection-molded guide (1) is actually embedded within the ring structure (3), the drawing in Figure 1 indicates the position of the injection-molded guide (1) within the ring structure (3) by a dashed line within the ring structure (3). As shown in Figure 1, the injection-molded guide (1) has the appearance of an annular ring when viewed from above the contraceptive device.

[0018] FIG. 2 shows a schematic partial side view of the exemplary contraceptive device shown in FIG. 1 , particularly a partial side view of the area identified as region "A" in FIG. 1 , which shows a cross-section of the contraceptive device, including a cross-section of a portion of exemplary injection-molded guide (1), a cross-section of a portion of porous barrier material (2), and a cross-section of a portion of ring structure (3). As shown in FIG. 2 , exemplary injection-molded guide (1) can include an L-shape including multiple planar surfaces (in this case, five planar surfaces) when viewed in partial cross-section. Thus, injection-molded guides of the present disclosure can have the appearance of an annular ring (when viewed from above) and can include multiple planar surfaces (when viewed in cross-section). In one embodiment, the injection molding apparatus has a base surface located adjacent to the porous barrier material, which is a planar surface and can optionally extend into openings in the porous barrier material, as shown in FIG. 2 .

[0019] The contraceptive devices of the present disclosure may be prepared from, and optionally comprise, a construct comprising a barrier material in contact with, and optionally secured to, an injection molded guide. The construct is particularly useful in the disclosed method for forming the contraceptive devices of the present disclosure, in which a ring structure is added to the construct comprising the barrier material and the injection molded guide.

[0020] In one embodiment, the construct is placed in a cavity (also called a mold, die, or chamber) that can receive molten polymer during a polymer injection molding process. The molten polymer is injected into the mold to form a ring structure. During this injection molding process, it is desirable to hold the construct securely in place so that both the barrier material and the injection molding guide do not move while the molten polymer is being injected into the mold under force. To this end, after the construct is placed in the mold, multiple movable pins are brought into contact with the surface of the injection molding guide, e.g., the flat surface of each pin is pressed against the flat surface of the injection molding guide, so that the pins hold the injection molding guide in a fixed position within the mold. Thus, the injection molding guide has a configuration that allows the guide to be centered within the injection molding die. The injection molding guide can also allow the pins of the injection molding die to directly contact the injection molding guide rather than the mesh. This reduces harmful mechanical shock to the mesh that occurs when the pins are placed within the mesh. The barrier material is held between the bottom of the mold and the injection mold guide, and optionally is rigidly secured to the injection mold guide, such that when the pin secures the injection mold guide within the mold, the barrier material is secured in place within the mold. After the pin contacts the injection mold guide, molten polymer is injected into the mold around and at least partially embeds the injection mold guide. Upon cooling, the molten polymer forms the ring structure of the contraceptive device of the present disclosure.

[0021] In one embodiment, the ring structure is added to a construct comprising a barrier material and an injection molding guide. In this method, the construct is placed in a heated or heatable cavity (also called a mold or chamber), which can receive a two-part thermosetting polymer mixture during the injection molding process. The liquid polymer mixture is injected into the mold to form the ring structure. During this injection molding process, it is desirable for the construct to be held firmly in place so that both the barrier material and the injection molding guide do not move while the liquid polymer mixture is being injected into the mold under force. To this end, after the construct is placed in the mold, a set of movable pins is brought into contact with one or more surfaces (e.g., planar surfaces) of the injection molding guide, pressing the surface of each pin against the surface of the injection molding guide so that the pins hold the injection molding guide in a fixed position within the mold. Thus, the injection molding guide has a configuration that allows the injection molding guide to be placed in a predetermined location within the injection molding die and firmly held in place during the injection molding process to form the polymer ring. The injection molding guide preferably has a symmetrical shape to facilitate this injection molding process. The injection molding guide may also allow the pins of the injection molding die to directly contact the injection molding guide rather than the mesh. This reduces harmful mechanical shock to the mesh that occurs when the pins engage with, i.e., are placed against, the mesh. The barrier material is held between the bottom of the mold and the injection molding guide, and optionally is securely fastened to the injection molding guide, so that when the pins secure the injection molding guide within the mold, the barrier material is fixed in place within the mold. After the pins are brought into contact with the injection molding guide, a liquid polymer mixture is injected into the mold so as to surround, at least partially embed, and optionally completely embed the injection molding guide. The liquid polymer mixture is held in the heated mold at a specified temperature for a time period to allow the liquid polymer mixture to harden (also known as crosslinking) into a solid polymer form, which forms the ring structure of the contraceptive device of the present disclosure. The formed contraceptive device is then removed from the mold.

[0022] The ring structure desirably forms the outer edge of the contraceptive device of the present disclosure. That is, the polymer ring may surround the periphery of the porous barrier material. Thus, in both the construct and the contraceptive device, the injection-molded guide is desirably located at or near the outer edge of the barrier material. The outer edges of each of the barrier material and the injection-molded guide can be described as circular, as shown in FIG. 1. Optionally, the barrier material is substantially circular. In one embodiment, the outer edge of the injection mold guide is coincident with, i.e., flush with, the outer edge of the barrier material. In another embodiment, shown in Figure 2, the outer edge of the injection mold guide is slightly inside the outer edge of the barrier material, e.g., in embodiments, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 mm of barrier material extends beyond the outer edge of the injection mold guide. In another embodiment, the outer edge of the injection mold guide is slightly beyond or outside the outer edge of the barrier material, e.g., in embodiments, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 mm of injection mold guide extends beyond the outer edge of the barrier material.

[0023] Barrier Materials The barrier materials of the present disclosure can delay the passage of sperm through the barrier material, but do not substantially impede the ability of vaginal fluids to pass through the barrier material. The barrier material can include one or more polymers. The polymers that can be used in the devices of the present disclosure can be non-absorbable, absorbable, or a combination thereof. Suitable absorbable and non-absorbable polymers are described herein below. In one embodiment, the barrier material can include a metal. For example, the mesh can be a wire mesh. In one embodiment, the mesh is a stainless steel mesh. The barrier material may be circular and therefore have a diameter. In one embodiment, the diameter of the barrier material is in the range of about 40 to 60 mm. The barrier material may have a diameter of at least 40 mm, e.g., at least 41 mm, or at least 42 mm, or at least 43 mm, or at least 44 mm, or at least 45 mm, or at least 46 mm, or at least 47 mm, or at least 48 mm. The barrier material may have a diameter of less than 60 mm, e.g., less than 59 mm, or less than 58 mm, or less than 57 mm, or less than 56 mm, or less than 55 mm, or less than 54 mm, or less than 53 mm, or less than 53 mm, or less than 52 mm, or less than 51 mm. In an embodiment, the barrier material has a diameter within a selected range from any of the minimum diameters noted above to any of the maximum diameters noted above, e.g., a diameter within the range of about 45 mm to about 53 mm. The barrier material may be described as being substantially flat, the diameter of which is much greater than the thickness of the barrier material. In one aspect, the barrier material may be non-circular. The barrier mesh may be rectangular, square, pentagonal, hexagonal, heptagonal, or octagonal. The physical barrier material of the contraceptive device can be a knitted or woven mesh. The knitted or woven mesh can include one or more fibers or yarns. In embodiments, the barrier material has a form selected from a porous mesh, an open-cell foam, a porous nonwoven material, and a porous film. In one embodiment, the barrier material is porous. In one embodiment, the barrier material is a mesh. In one embodiment, the barrier material is fibrous. In one embodiment, the barrier material is a mesh formed from fibers, i.e., a fibrous mesh.

[0024] The absorbable and non-absorbable polymers described herein can be formed into fibers suitable for forming barrier materials. Fibers can be produced from the polymers by an extrusion process. The extrusion process can include heating the polymer to a flowable temperature and then forcing the polymer through an opening of a defined shape and size. Fibers can be round, oval, square, rectangular, irregular, bilobal, or trilobal. In an optional embodiment, the fiber may have a cross-sectional dimension of 5 μm to 600 μm. In one aspect, the fiber cross-sectional dimension is 20 μm to 300 μm. A monofilament fiber is a single fiber. A yarn comprising a monofilament fiber can be called a monofilament yarn. A preferred cross-sectional dimension of a monofilament is 40 μm to 400 μm. A more preferred cross-sectional dimension of a monofilament is 80 μm to 200 μm.

[0025] In one embodiment, two or more fibers can be formed into a multifilament yarn, which can be used to form a barrier material. In one embodiment, the yarn can contain 2 to 100 fibers. In a preferred embodiment, the yarn can contain 30 to 90 fibers. In one embodiment, the yarn can contain 86 fibers. In another embodiment, the yarn can contain 43 fibers. The final yarn can be made by twisting two or more yarns together. In one embodiment, the number of fibers in each of the yarns to be twisted is the same. For example, a 43-fiber multifilament yarn can be twisted with a second 43-fiber multifilament yarn to form a ply yarn containing 86 fibers. In another embodiment, the number of fibers in each of the yarns to be twisted is different. For example, a 43-fiber multifilament yarn can be twisted with a second 35-fiber multifilament yarn to form a ply yarn containing 78 fibers. The ply yarn can have a total filament count of 2 to 200. In one embodiment, the total number of filaments is 40 to 120. In one embodiment, the ply yarn has 86 fibers. The multifilament yarn can be made from fibers of the same composition, or can be made using fibers of two or more different compositions. In this case, a blended yarn is obtained. In one embodiment, the yarn can be absorbable. In another embodiment, the yarn can be non-absorbable. In another embodiment, the yarn can include absorbable and non-absorbable fibers. Multifilament yarns can be made without twisting the fibers. In one embodiment, the yarns can be flat yarns. In one embodiment, the yarns can be twisted yarns. In one embodiment, the yarns can have a twists per inch (TPI) of 1 to 7. In a preferred embodiment, the yarns can have 2 to 6 TPI. In one embodiment, the yarns can have an average of 2 TPI, 3 TPI, 4 TPI, 5 TPI, or 6 TPI. Optionally, one or more fibers may be oriented by stretching the fibers prior to use in forming the barrier material.

[0026] In one aspect, the yarn can be textured. Textured yarns are produced using various twisting, mechanical, and heat-setting techniques that create a crimping effect that makes the yarn thicker and softer, and in some cases imparts stretchability to the yarn. In one aspect, the yarn can be twisted, heat-set in its twisted configuration, and then untwisted. The yarn then assumes a helical shape that imparts stretch and fluffiness to the yarn. In one aspect, the yarn can be crimped. The yarn is tightly packed into a chamber of a predetermined shape and then heat-set within this confining structure. Upon removal from the confining structure, the yarn assumes a stretchable form. In one aspect, the yarn can be a trap yarn (loop yarn). Trap yarns are produced by exposing a multifilament yarn to a jet of pressurized air, a technique known as air-jet texturing or air texturing. Each of the above yarns is used in barrier materials for constructs or contraceptive devices of the present disclosure.

[0027] In one embodiment, the yarn of the barrier material can be in the form of a staple yarn. Staple yarns are formed by using relatively short fibers, carding the fibers, and then drawing and spinning them to create a yarn. If highly aligned fibers are desired, the carded fibers can be combed to further align the fibers. Staple yarns can be made from fibers of the same composition, or can be made using fibers of two or more different compositions, resulting in a staple yarn. In one embodiment, the staple yarn can be absorbent. In another embodiment, the staple yarn can be non-absorbent. In another embodiment, the staple yarn can include absorbent and non-absorbent fibers. In one embodiment, the yarn can be an abraded yarn. The denier of a fiber or yarn is measured as the mass in grams of 9000 meters of the fiber or yarn. For monofilament fibers or multifilament yarns, the denier of the fiber or yarn used to form the barrier material may be from 1 to 800. In one embodiment, the denier of the fiber or yarn is from 30 to 300. In another embodiment, the denier is from 50 to 250. Another way to characterize a fiber or yarn is by using the denier per filament. The denier per filament (DPF) is calculated by dividing the denier of the yarn by the number of filaments that make up the yarn. In one embodiment, the DPF of the yarn or fiber used to form the barrier material is from 1 to 25. In another embodiment, the DPF is from 2 to 10.

[0028] The fibers of the barrier material may further comprise a dye. In one embodiment, the dye can be incorporated into the fiber or yarn during the extrusion process. In another embodiment, the dye can be applied as a coating onto the finished fiber or yarn. In another embodiment, the dye can be incorporated into the fiber or yarn by dyeing the material. The dyeing process can be accomplished by immersing the fiber or yarn in a solution of the dye and allowing the dye to diffuse into the fiber or yarn. Examples of dyes that can be used include, but are not limited to, D&C Violet No. 2, (phthalocyaninato[2]) copper, logwood extract, D&C Green No. 5, D&C Green No. 6, chromium-cobalt-aluminum oxide, FD&C Blue No. 2, and D&C Blue No. 6.

[0029] After extrusion of one or more fibers and before forming the fibers into a barrier material, a spin finish can be applied to the fibers, which can act as a lubricant, antioxidant, or antistatic agent. Spin finishes include, but are not limited to, glycerin, poly(ethylene glycol) dioleate Esterol 244, magnesium stearate, isocetyl stearate, alkyl stearates, alcohol ethoxylates or alkylphenol ethoxylates, butyl stearate, alkyl polyoxyethylene carboxylate esters, polyalkylene glycol (200) monolaurate, polyalkylene glycol (600) monoisostearate, ethoxylated propoxylated butyl alcohol, POE(5) potassium lauryl phosphate, POE(30) castor oil, Lurol 1187 (Goulston Inc., 700 N. Johnson Street, Monroe, NC 28110), Lurol PT-6A, LUROL FR-L987, LUROL PS-14135, LUROL PS-11158, LUROL PS-662, LUROL SF-14974, LUROL Examples of suitable finishes include PS-9725, LUROL-SF-13191, LUROL SF-15361, LUROL SF-15704, LUROL SF-15628, PS-662, PS-13460, LUROL PP-912, Lurol® SF-563, Lurol® SF-565, Lurol® SF-567, Lurol P1 801 (Goulston), Lurol PT-L216 (Goulston), Stantex 6457 (Pulcrachem), Esterol PF-790 (Bozzeto GmbH), Estesol TXB (Bozzetto Group), and Filapan CTC (Boehme). Spin finishes from Dow, such as SYNALOX® 50-30B and SYNALOX® 50-50B, can also be used. In one embodiment, the spin finish is Lurol PT-6A. In one embodiment, the spin finish is glycerin.

[0030] In one embodiment, the barrier material is a knitted mesh. The knitted mesh may include one or more non-absorbent fibers or yarns, one or more absorbent fibers or yarns, or a combination thereof. Warp knitting or weft knitting can be used to manufacture the knitted mesh. For warp-knitted barriers, conventional, well-known warp knitting equipment and techniques can be used. Such equipment and techniques are described in "Knitting Technology, A Comprehensive Handbook and Practical Guide" by David J. Spencer (3rd Edition, 2001 Woodhead Publishing Limited and Technomic Publishing Company Inc., ISBN 185573331), the contents of which are incorporated by reference. A tricot knitting machine can be used to knit the barrier material. The tricot machine can have two, three, or four reeds. In a preferred embodiment, the knitting machine has two reeds. A Russell knitting machine can be used to knit the barrier material. The construction of the knitted mesh of the barrier material can be specified in terms of the number of courses per inch and wales per inch for any given yarn, as well as the specific knit design. In one embodiment, the knitted barrier has courses per inch ranging from 4 to 80. In another embodiment, the courses per inch is from 10 to 40. In another embodiment, the courses per inch is from 20 to 40. In one embodiment, the barrier knitted mesh has 9 to 44 wales per inch. In another embodiment, the barrier knitted mesh has 15 to 35 wales per inch. In another embodiment, the knitted barrier mesh has 15 to 25 wales per inch.

[0031] Knit patterns for the knitted barrier mesh include, but are not limited to, lock knit, reverse lock knit, tricot jersey, tricot satin, half tricot, two-bar tricot, sharkskin, or queens cord patterns. In another embodiment, the knit pattern is marquisette. Barrier materials are available from Surgical Mesh (72 Grays Bridge Road Unit D1, Brookfield, Connecticut, 06804, USA) under part numbers PETKM2002, PETKM2004, PETKM2006, PETKM2007, PETKM2008, PETKM2009, PETKM3002, PETKM3003, PETKM7002, PETKM14002, PPKM301, PPKM302, PPKM14002, PPKM301, PPKM302, PPKM14003, PPKM14004, PPKM14005, PPKM14006, PPKM14007, PPKM14008, PPKM14009, PPKM140 ...9, PPKM14002, PPKM14003, PPKM14004, PPKM14005, PPKM14006, PPKM14007, PPKM1 PPKM403, PPKM404, PPKM405, PPKM406, PPKM407, PPKM409, PPKM501, PPKM502B, PPKM503, PPKM505, PPKM506BS, PPKM601, PPKM603, PPKM604, PPKM605, PPKM606, PPKM607BS, PPKM608B, PPKM801, PPKM802 AND PPKM 807). In one embodiment, the barrier material has a knit pattern similar to that of part numbers RJ27, XT34, XA90, TG77, TF40, RG90, RG26, RG06, RF99, RB88, RB61AF, PR95, PQ15, NZ74, NX91, NT55, NP61, NK50A, NK47A, NJ85, ND29, ND27, NB63, N98, LF2, AROWLN, NZ11, RC08, PV57 manufactured by Apex Mills, 168 Doughty Boulevard, Inwood, NY 11096, USA. In one embodiment, the barrier material is a knitted material with approximately 38 courses per inch and has a two-reed tricot knit pattern.

[0032] The barrier material of the contraceptive device can also be manufactured using a weaving process. In one embodiment, the warp thread count of the woven barrier ranges from 4 to 40. In another embodiment, the warp thread count ranges from 5 to 20. The woven barrier material may have a fill thread count of 2 to 44. In another embodiment, the woven barrier material may have a fill thread count of 3 to 20. Optionally, the woven barrier material may have weft and warp threads of the same material. However, in one embodiment, the weft and warp thread materials are different. In one embodiment, the materials used to manufacture the woven barrier can be absorbable, non-absorbable, or a combination thereof. The weave pattern of the barrier material may be similar to that of part numbers PETWM707001 and PETWM757501 from Surgical Mesh, Inc. (72 Grays Bridge Road Unit D1, Brookfield, Connecticut, 06804, USA). The barrier material may be manufactured using a meltblown process. In this process, thermoplastic polymer granules are melted and passed through an extruder. The molten polymer is then passed through a nozzle block having one or more heated gas outlets. After passing through the extruder nozzle tip, the polymer is stretched into fibers by compressed heated gas. The fibers are blown onto a gas-permeable mesh belt, completing the formation of meltblown fibers. Gases that can be used include, but are not limited to, air, nitrogen, argon, or a combination of two or more of these gases. Barrier materials produced using the meltblown process can contain a single polymer or can contain two or more polymers. In one aspect, two polymer granules are fed into an extruder simultaneously to produce a single barrier material having fibers containing a blend of two or more polymers. In another aspect, the barrier material has a laminated structure. In one embodiment, a laminated structure can be produced by creating a first layer of meltblown material and then blowing a second layer onto the first layer to form a second layer of meltblown fibers. This forms a two-layer laminate structure. To form a three-layer laminate structure, this process can be repeated, with a third layer applied to the second layer. The two layers of the two-layer laminate structure can have the same polymer composition, or the two layers can have different polymer compositions. In a three-layer laminate, the layers can have the same polymer composition, different polymer compositions, or two layers can have the same polymer composition and a third layer with a different polymer composition.

[0033] The meltblown layer can be formed on a polymer mesh that is knitted, woven, or nonwoven. In one embodiment, a two-layer laminate structure can be created with a meltblown layer covering or interpenetrating a mesh layer. In another embodiment, a three-layer laminate structure can be created with a mesh sandwiched between two meltblown layers. In another embodiment, a second meltblown layer can be applied on top of the first meltblown layer to obtain a three-layer laminate structure with a mesh base layer followed by two meltblown layers. In one embodiment, the mesh and the meltblown layer have the same polymer composition. In another embodiment, the mesh and the meltblown layer have different polymer compositions. The porosity and pore size of the meltblown layer can be controlled by a combination of nozzle diameter, extrusion temperature, compressed gas temperature, polymer extrusion rate, compressed heated gas flow rate, nozzle distance from the collection mesh, and collection mesh speed. For a laminated structure, the pores of the layers can be approximately the same size. In one aspect, the pores of the laminates can be different.

[0034] The barrier material of the contraceptive device can be manufactured using a spunbond process, a nonwoven carding process, a nonwoven airlaid process, or a nonwoven wetlaid process. Alternatively, a combination of processes can be used to manufacture the barrier material. For example, the barrier material may be manufactured using a meltblown process and a spunbond process. A meltblown process and a spunbond process may be used to manufacture a spun-melt-spun laminate structure. The mechanical properties of a material manufactured using one of the above processes can be improved by using a bonding process. Thermal bonding, sonic bonding, chemical bonding, or mechanical bonding are suitable options. Thermal bonding processes include, but are not limited to, flat bonding, point bonding, or through-air bonding. In flat bonding, heat and pressure are applied to a material in the form of a flat calender. Flat bonding involves the application of a heated roll embossed with a specific pattern. The fibers are then bonded where the roller pattern contacts the fibers. The through-air bonding process involves passing the fabric through a heated drum, creating a bond throughout the fabric.

[0035] In one embodiment, the barrier material is manufactured using an electrospinning process. In this process, a solution of polymer is pumped through a nozzle and collected on a collection plate. This process is driven by a large potential difference between the nozzle and the collection plate. The material on the collection plate is in the form of a nonwoven mesh with fibers ranging from 0.2 to 50 μm. In one embodiment, the collection plate can be a rotating drum. In one embodiment, the drum can be rotated at a speed of about 10 rpm up to about 500 rpm. In one embodiment, the speed of the collection drum can be increased to align the fibers. The higher the rotation speed, the greater the degree of fiber alignment achieved. In one embodiment, the drum can be rotated at greater than about 500 rpm up to about 1000 rpm. In one embodiment, the electrospun material can be made using a blend of two or more polymer solutions. In another embodiment, the material can be made using two or more separate polymer solutions pumped through separate nozzles. The electrospun barrier material can include one or more absorbable polymers, one or more non-absorbable polymers, or a combination thereof.

[0036] In one embodiment, the barrier material is manufactured in the form of a film, which has a series of holes or fenestrations therein to allow the film to pass water. The film may be made, for example, by solvent casting, extrusion, or mechanical compression. Holes in the film may be introduced by mechanically punching the film, laser drilling holes, or by using a porogen that dissolves from the film, leaving a porous structure. Porogens that can be used include, but are not limited to, sodium chloride, sucrose, or polymers soluble in a non-solvent for the polymer used to make the film. Fenestrations may be introduced by stamping or roller-cutting the film. Film-based barrier materials may include one or more absorbent polymers, one or more non-absorbent polymers, or a combination thereof. In one embodiment, the barrier material is made by laminating two or more barrier materials together. In one embodiment, the barrier materials used in the lamination are manufactured using the same process. In another embodiment, the barrier materials used in the lamination are manufactured using different processes. For example, a knitted mesh can be laminated with a meltblown mesh. Any combination of barrier materials using different manufacturing processes can be laminated together to form the final barrier material containing the contraceptive device or its precursor construct.

[0037] In one embodiment, the barrier material used in the contraceptive device or precursor construct thereof comprises a porous material. The barrier material has porosity that allows water to pass through the barrier material. In another embodiment, the barrier material allows simulated vaginal fluid to pass through it as defined by Marques et al. (Marques, MRC, Loebenberg, R., & Almukainzi, M. (2011) Dissolution Technologies, 18(3), 15-28). In one embodiment, aqueous solutions can pass through the barrier membrane at a flow rate of at least 50 mL / min. In one embodiment, the barrier material has a water flow rate through the barrier membrane of 2 gal / min / sq ft to 500 gal / min / sq ft. In one embodiment, the barrier material has a water flow rate through the barrier membrane of 10 gal / min / sq ft to 300 gal / min / sq ft. In one embodiment, the barrier material has a water flow rate through the barrier membrane of 50 gal / min / sq ft to 250 gal / min / sq ft. The barrier material may have a range of pore sizes. The pore size, measured across a short distance between one side of the pore and the other side of the pore, may be 50 μm to 500 μm. In one embodiment, the average pore size is 80 μm to 300 μm. In one embodiment, the average pore size is 90 μm to 250 μm. In one embodiment, the pore sizes may be homogeneous, with a relative standard deviation of the measured pore sizes being less than 10%. In one embodiment, the pore sizes may be heterogeneous, with a relative standard deviation of the measured pore sizes being greater than 10%.

[0038] Barrier materials may be subjected to post-manufacturing treatments, including but not limited to cleaning, heat treatment, surface treatment, coating, and sterilization.

[0039] The barrier material can be washed with a non-solvent for the polymer. The solvent used to wash the mesh can be a non-aqueous solvent, an aqueous solvent, or a combination of aqueous and non-aqueous solvents. Non-aqueous solvents include, but are not limited to, methanol, ethanol, 2-isopropyl alcohol, acetone, ethyl acetate, methyl ethyl ketone, methyl tert-butyl ether, toluene, cyclohexane, and hexane. Aqueous solvents include, but are not limited to, water, deionized water, saline, phosphate buffered saline, aqueous base solutions, sodium hydroxide solutions, aqueous acids, and hydrochloric acid solutions. The barrier material can be washed in a batch process or using a continuous process. The washing step can be used to remove particulate matter, impurities, fiber lubricants, spin finishes, extrusion aids, or combinations thereof. In one embodiment, the barrier material can be washed with isopropyl alcohol in a batch process. The washing step can be repeated one or more times until the desired specifications are met. In one embodiment, the barrier material is washed at least twice with isopropyl alcohol to reduce residual fiber lubricant or spin finish to a level that is non-cytotoxic in an in vitro cell assay. In one embodiment, the washing process can reduce the fiber lubricant or spin finish content by at least 50% (w / w) compared to an unwashed barrier material. In another embodiment, the washing process can reduce the fiber lubricant or spin finish content by at least 90% (w / w) compared to an unwashed barrier material. In one embodiment, the residual fiber lubricant or spin finish in the final barrier material can be less than about 4% (w / w), about 3% (w / w), about 2% (w / w), about 1% (w / w), or about 0.5% (w / w). In a preferred embodiment, the residual fiber lubricant or spin finish in the final barrier material can be less than about 0.2% (w / w). In one embodiment, the residual fiber lubricant or spin finish in the final barrier material can be greater than about 0.01% (w / w) and less than about 0.2% (w / w). In one embodiment, the final barrier material is free of fiber lubricant or spin finish. After washing, the barrier material can be air dried, dried under a stream of gas, dried under a stream of heated gas, dried under vacuum, heated and dried under vacuum, or a combination of the above.

[0040] The barrier material can be subjected to a heat treatment. The barrier material can be heat-cured or annealed. In a heat-curing process, the barrier material is heated above the glass transition temperature (Tg) of the material for a period of time. The material is then cooled to room temperature. The heat-curing process can increase the stability of the barrier material, for example, it can increase the thermal stability of the barrier material and / or it can increase the physical stability of the barrier material. In one embodiment, the heat-curing process increases the mechanical stability of the barrier material. Heat-curing the barrier material reduces the rate of dimensional change of the barrier compared to a non-heat-cured barrier material. Parameters that can be used to modify the heat-curing of the barrier material include temperature, exposure time to a particular temperature, tension applied to the barrier material during heat-curing and cooling, humidity of the environment used for heat-curing, and the medium used for heat-curing. In one aspect, the heat-curing medium can be heated air. In one aspect, the heat-curing medium can be a non-solvent liquid. In one aspect, the heat-curing medium can be a heated surface. The heat-curing process can be performed in a continuous or batch process. A tenter frame can be used to perform continuous heat-curing. A pin frame can be used to heat-set the barrier material in a batch process. In one aspect, the barrier material can be heat-set by passing the material through a set of heated calender rollers. The pressure applied to the barrier material while passing through the calender rollers can be adjusted. The porosity of the barrier material can also be altered by passing the barrier material through heated calender rollers.

[0041] Injection Molding Guide In one aspect, the injection molding guide is not attached to the barrier material prior to injection molding of the ring component. However, in one aspect, the injection molding guide is secured to the barrier material to form a construct that is placed in a die of an injection molding apparatus prior to injection molding of the ring component. When the injection molding guide is secured to the barrier material, the entire surface of the injection molding guide may be secured to the barrier material to maintain the injection molding guide in contact with the barrier material during injection molding of the ring component, or in one aspect, less than the entire surface, e.g., only one or more portions of the surface, may be secured to the barrier material. The injection-molded guide may be a solid, non-fibrous, or fibrous layer. In one embodiment, the injection-molded guide is non-fibrous; it may comprise a polymer, and optionally be formed entirely of a polymer. In one embodiment, the injection-molded guide comprises a thermoplastic polymer. In one embodiment, the injection-molded guide comprises a thermosetting polymer, e.g., a heat-cured polymer, also known as a heat-set polymer, formed by mixing two mutually reactive polymers (a thermosetting mixture) to form a so-called heat-set polymer. In one embodiment, the injection-molded guide is non-fibrous and comprises a thermosetting polymer. When injection molding guides are attached to the barrier material to form the construct, the injection molding guides may be or are attached to the barrier material towards the outer edge of the barrier material. The injection molding guides are attached to the barrier material so that the barrier material is easily centered in the injection mold and held in a desired, predetermined position during molding of the ring portion of the contraceptive device. The injection molding guide can have a variety of cross-sectional shapes. Examples of cross-sectional shapes of the injection molding guide include, but are not limited to, square, rectangular, L-shaped, T-shaped, offset T-shaped, U-shaped, V-shaped, partial V-shaped, hemispherical, or irregular. In cross-section, a square or rectangular injection molding guide will have four corners, an L-shaped injection molding guide will have six corners, and a T-shaped injection molding guide will have eight corners. In one embodiment, the injection molding guide can be attached to the barrier on only one side of the barrier material. In another embodiment, the injection molding guide can be attached to the barrier on both sides of the barrier material. The injection molding guide can cover a portion of the surface of the barrier material, in which case the portion of the barrier material not covered by the injection molding guide is porous as described herein.

[0042] The injection-molded guides of the constructs and contraceptive devices of the present disclosure may be fabricated by any convenient means. For example, the injection-molded guide may be a plastic part fabricated by injection molding. If the injection-molded guide is fabricated independently from the barrier material, it is secured to the barrier material, for example, using an adhesive. As another example, the injection-molded guide may be fabricated by 3D printing and then secured to the barrier material. 3D printing, extrusion, solvent casting, or injection molding are all suitable means for manufacturing the injection-molded guide. In one embodiment, the injection-molded guide comprises a thermoplastic polymer. In one embodiment, the injection-molded guide comprises a thermosetting polymer. In one embodiment, the injection-molded guide is non-fibrous and comprises a thermoplastic polymer. In one embodiment, the injection-molded guide is non-fibrous and comprises a thermosetting polymer, for example, a heat-cured polymer. As described above, the injection-molded guide can be manufactured separately and then attached to the barrier material to secure the injection-molded guide to the barrier material. The formed injection-molded guide can be attached to the barrier using an adhesive. Adhesives that can be used include, but are not limited to, solvent-based adhesives, contact adhesives, hot-melt adhesives, two-part adhesives, or reactive adhesives such as cyanoacrylate adhesives. In one embodiment, the solvent-based adhesive can be a polyester dissolved in acetone or dichloromethane. In one embodiment, the polyester can be a polymer containing lactide residues. In one embodiment, the polyester can be a polymer containing ε-caprolactone residues. The formed injection-molded guide can be attached to the barrier using an ultrasonic welding process, a laser welding process, an embroidery process, or a hot stamping process (in which one surface of the injection-molded guide is heated and pressed against the barrier).

[0043] In one embodiment, the injection-molded guide is 3D printed directly onto the barrier material. The 3D printing process may optionally utilize fused fiber filament (FFF) 3D printing. In this embodiment, the barrier material may be porous, such that the molten polymer used in the 3D printing process flows, to some extent, into the openings in the barrier material. Upon cooling, the 3D-printed polymer hardens and embeds portions of the barrier material. In this manner, the injection-molded guide becomes physically fixed to the barrier material. In this embodiment, the melting point of the polymer used to form the injection-molded guide should not be substantially higher than the melting point of the material used to form the barrier material; otherwise, the barrier material may undesirably melt during the 3D printing process. However, the melting point of the polymer used to form the injection-molded guide must not be too low, otherwise, when the molten polymer used to form the ring structure of the contraceptive device is added to the construct, the injection-molded guide may become warm enough to deform during the injection molding process. In one embodiment, the injection-molded guide is thermoplastic and has a melting point above the temperature used for injection molding. In embodiments, the melting point of the polymer used to form the injection-molded guide is greater than 110°C, or greater than 120°C, or greater than 130°C, or greater than 140°C, or greater than 150°C, or greater than 160°C, or greater than 170°C, or greater than 180°C, or greater than 190°C, or greater than 200°C. In one embodiment, the injection-molded guide is made from a cross-linked polymer and therefore does not have a melting or softening point. Cross-linked polymers may be formed by a thermosetting process, in which two multifunctional and mutually reactive reactants, such as reactive polymers, are combined and then reacted with each other, such as by heat or the addition of a catalyst. In one embodiment, the injection molding guide does not have a melting or softening point.

[0044] In one embodiment, the injection molded guide has a homogenous composition throughout the structure of the guide. In other words, the guide has the same composition everywhere in the guide. In one embodiment, the guide contains or does not have a coating, for example, the guide does not have a sizing polymer. In one embodiment, the injection molded guide contains or does not have yarns or multifilament threads. In one embodiment, the injection molded guide can be said to be non-fibrous. In one embodiment, the injection molded guide may have a non-yielding or non-compressible surface, such that it does not move or yield or compress to any appreciable extent when pressure is applied to the surface. In one embodiment, the injection molded guide is not formed from an elastic polymer, i.e., is non-elastic. In one embodiment, the injection molded guide can be described as non-porous.

[0045] In one embodiment, the injection molding guide has a uniform cross-section. In other words, the cross-section of the injection molding guide viewed from anywhere along the diameter of the injection molding guide has the same appearance. This feature is advantageous in that when the build is placed in the mold prior to the formation of the support ring, the pins that contact the surface of the injection molding guide can all move the same distance to contact the surface of the injection molding guide. If the injection molding guide had a non-uniform cross-section, some pins may have to move farther than others to contact the surface of the injection molding guide.

[0046] Exemplary partial cross-sectional views of injection molding guides of the present disclosure are shown in Figures 2, 3A-3I, 4, 5A, and 5B, where feature 1 is the injection molding guide and feature 2 is a porous barrier material. Figure 6A shows a top view of a construct of the present disclosure comprising an injection molding guide 1 and a porous barrier material 2. In one embodiment, the construct of the present disclosure consists of, or consists essentially of, an injection molding guide and a porous barrier material. Figure 6A shows line B intersecting the construct shown in Figure 6A. When the construct of Figure 6A is viewed in cross section along line B, a full cross-section of the construct is shown in Figure 6B, showing the porous barrier material 2 and two injection molding guides 1, labeled 1R and 1L in Figure 6B. When the structure of FIG. 6A is viewed in partial cross section, only one of the two injection molding guides 1 is visible, as shown in the schematic diagram of FIG. 6C, which is the portion of the structure of FIG. 6A, more specifically the portion enclosed by area C in FIG. 6C showing the outline of injection molding guide 1R. When an injection molding guide is viewed in full cross section along its diameter, the full cross section shows two shapes (e.g., see features 1R and 1L in FIG. 6B ) separated by the inner diameter of the injection molding guide (see feature 2 in FIG. 6B ) because the injection molding guide has an annular shape and thus may be in the form of a ring. For convenience, only one of these two shapes is shown in each of FIGS. 2 , 3A-3I , 4 , 5A , 5B , and 6C , which show partial cross sections of the injection molding guide and porous barrier material. When an injection molding guide is symmetrical in that it has a uniform cross section when viewed in full cross section along its diameter, the full cross section shows two complementary shapes separated by a distance representing the inner diameter of the annular injection molding guide, and these complementary shapes are identical in appearance and size regardless of which diameter of the injection molding guide is selected for the cross section. The complementary shapes may be mirror images of each other, with the center point of the annular injection molding guide as a reflection point; in other words, one shape (e.g., hemisphere 1L in FIG. 6B) is a mirror image of the other shape (e.g., hemisphere 1R in FIG. 6B). FIG. 6B shows a full cross-section of the construct of FIG. 6A, and FIG. 6C shows a partial cross-section of the construct of FIG. 6A. A symmetric injection molding guide may have a plane of symmetry. That is, a plane can be drawn on a diagram of the injection molding guide that cuts the injection molding guide into two mirror-image halves. A symmetric injection molding guide may have a line of symmetry, i.e., an axis or imaginary line that passes through the center of the injection molding guide and divides the injection molding guide into equal halves, particularly when the injection molding guide is viewed from above as in FIG. 1 or FIG. 6A.

[0047] As shown in FIG. 2 , in one embodiment, the injection molding guide can have an L-shaped cross-section. The L-shaped cross-section is advantageous in that it provides two planar surfaces that meet at a right angle to form a corner. When a construct is placed in a mold and the pins move to contact the injection molding guide, a surface of each pin can contact the injection molding guide when the injection molding guide has a corner formed from two planar surfaces. This method results in a particularly strong connection between the pins and the injection molding guide, thereby reducing the likelihood of the construct moving while the polymer that forms the ring structure is being injected into the mold. In aspects of the present disclosure, the injection molding guide comprises multiple planar surfaces, for example, two, or at least two, three, or at least three, four, or at least four, five, or at least five, six, or at least six planar surfaces. In one embodiment, the injection molding guide of the present disclosure comprises at least two planar surfaces that optionally intersect at a right angle to form a corner. FIG. 3 illustrates eight exemplary cross-sectional shapes of injection molding guides of the present disclosure. In FIGS. 3A, 3B, 3G, and 3H, the injection molding guide has an L-shaped cross-sectional shape. In FIGS. 3D, 3E, and 3F, the injection molding guide has a T-shaped cross-sectional shape. In FIG. 3C, the injection molding guide has a U-shaped cross-sectional shape. Comparing FIGS. 3A and 3I, the injection molding guides have the same cross-sectional shape. However, in FIG. 3A, the outer edge of the injection molding guide coincides with the other edge of the barrier material, whereas in FIG. 3I, the outer edge of the barrier material extends beyond the outer edge of the injection molding guide. In one embodiment, the injection molding guide can be positioned flush with the outer periphery of the barrier. In one embodiment, the injection molding guide can be positioned so that there is a space between the edge of the injection molding guide and the outer periphery of the barrier. In each of the constructions shown in Figures 3A-3I, the injection molding guide has multiple planar surfaces. In Figure 3A, the injection molding guide has six planar surfaces, two of which meet at right angles to form one corner. In Figure 3B, the injection molding guide has six planar surfaces, two of which meet at right angles to form one corner. In Figure 3C, the injection molding guide has eight planar surfaces, three of which meet at right angles to form two corners. In Figure 3D, the injection molding guide has eight planar surfaces, four of which meet at right angles to form two corners. In Figure 3E, the injection molding guide has eight planar surfaces, four of which meet at right angles to form two corners. In Figure 3F, the injection molding guide has eight planar surfaces, four of which meet at right angles to form two corners. In Figure 3G, the injection molding guide has six planar surfaces, two of which meet at right angles to form a corner. In Figure 3H, the injection molding guide has six planar surfaces, two of which meet at right angles to form a corner. In Figure 3I, the injection molding guide has six planar surfaces, two of which meet at right angles to form a corner. The presence of corners as an injection molding guide feature is useful because pins press against the corners of the injection molding machine, providing increased stability for the build within the mold. In one embodiment, the injection molding apparatus has a base surface located adjacent to the porous barrier material, the base surface being a planar surface, and as shown in Figures 3A, 3B, 3C, 3D, 3E, 3F, 3G, 3H and 3I, the base surface may optionally not extend into the openings of the porous barrier material, although the base surface of any of the shapes shown in Figures 3A, 3B, 3C, 3D, 3E, 3F, 3G, 3H and 3I may optionally extend into the porous barrier material.

[0048] In one embodiment, the L-shaped injection molding guide can be attached to the barrier as a base surface by the longer side of the L-shape. In one embodiment, the L-shaped injection molding guide can be attached to the barrier as a base surface by the shorter side of the L-shape. In one embodiment, the longer side of the L-shape can be attached to the barrier, and the shorter side of the L-shape can be near the outer edge of the barrier. In one embodiment, the longer side of the L-shape can be attached to the barrier, and the shorter side of the L-shape can be near the inner part of the barrier. In one embodiment, the shorter side of the L-shape can be attached to the barrier, and the longer side of the L-shape can be near the outer edge of the barrier. In one embodiment, the shorter side of the L-shape can be attached to the barrier, and the longer side of the L-shape can be near the inner part of the barrier. In one embodiment, the L-shape of the L-shaped injection molding guide has two equally sized arms that connect at a corner, and one of the two arms provides the base surface. In one embodiment, the long side of the L-shape attached to the barrier, i.e., the base surface, has a length of about 2 mm to about 10 mm. In one embodiment, the long side of the L-shape attached to the barrier has a length of about 3 mm to about 7 mm. In one embodiment, the long side of the L-shape attached to the barrier has a height of about 0.2 to about 2 mm. In one embodiment, the long side of the L-shape attached to the barrier has a height of about 0.3 to about 1 mm. In one embodiment, the short side of the L-shape has a height of about 0.2 to about 1.5 mm. In one embodiment, the short side of the L-shape has a height of about 0.3 to about 1 mm. In one embodiment, the short side of the L-shape has a height of about 0.5 to about 4 mm. In one embodiment, the short side of the L-shape has a height of about 0.7 to about 2.5 mm. In one embodiment, the L-shape of the L-shaped injection molding guide has two equal parts connected at a corner, and each part has a length of about 2 mm to about 10 mm.

[0049] The constructs and contraceptive devices of the present disclosure each include a barrier material and an injection-molded guide. As noted above, in one embodiment, the injection-molded guide can be attached to only one side of the barrier. However, in another embodiment, the injection-molded guide can be attached to both sides of the barrier material. This latter embodiment is illustrated in Figure 4. Figure 4 shows a schematic of an exemplary injection-molded guide (1) disposed on the barrier material (2) of an exemplary contraceptive medical device disclosed herein, with the injection-molded guide (1) secured to each of the top and bottom of the barrier material.

[0050] In one embodiment, the injection molding guide has a corner formed by the intersection of two planar surfaces. Optionally, the injection molding guide has a corner formed by two planar surfaces that intersect with each other at an angle of, for example, 85 to 90 degrees, or about 90 degrees, forming an angle of, for example, about 45 to about 135 degrees, or about 80 to about 100 degrees. Thus, as discussed above, the injection molding guide of the present disclosure may include a corner, where two planar surfaces meet at a right angle. However, in one embodiment, the injection molding guide of the present disclosure may have two planar surfaces that meet to form an angle other than about 90 degrees. For example, as shown in FIGS. 5A and 5B, the injection molding guide of the present disclosure may include two planar surfaces that intersect to form an angle of more than 90 degrees, such as 100 degrees, or more than 100 degrees. In one embodiment, the two planar surfaces intersect to form an angle less than 90 degrees, such as about 45 degrees. As illustrated in the series of Figures 6A, 6B, and 6C, the injection molded guide need not have only planar surfaces. As illustrated in the series of Figures 6A, 6B, and 6C, the injection molded guide can have curved surfaces, as shown by the outlines of features 1R and 1L in Figures 6B and 6C. The curved surfaces of the injection molded guide can uniformly engage with the pins of an injection molding machine if the injection molded guide is symmetrical, as shown in Figure 6BA. Thus, in one aspect, the present disclosure provides a contraceptive device including a polymer ring, a porous barrier material, and an injection molded guide, wherein the injection molded guide is symmetrical in cross section, and both the injection molded guide and the porous barrier material are at least partially embedded within the polymer ring.

[0051] In one embodiment, the injection molding guide can be described as an annular ring having an inner diameter and an outer diameter. In one embodiment, the inner diameter of the injection molding guide is about 42 mm to about 46 mm. In one embodiment, the outer diameter of the injection molding guide is about 45 mm to about 53 mm. In one embodiment, the injection molding guide can be non-circular. The barrier mesh can be rectangular, square, pentagonal, hexagonal, heptagonal, or octagonal.

[0052] The injection-molded guide may comprise one or more polymers described herein. In one embodiment, the injection-molded guide may comprise an absorbable polymer. In another embodiment, the injection-molded guide may comprise a non-degradable polymer. In one embodiment, the injection-molded guide comprises an absorbable polymer comprising more than 70% (w / w) lactide residues. In one embodiment, the injection-molded guide comprises an absorbable polymer comprising more than 80% (w / w) lactide residues. In one embodiment, the injection-molded guide comprises an absorbable polymer comprising about 70% (w / w) to about 90% (w / w) lactide residues and 10% (w / w) to 30% (w / w) trimethylene carbonate residues. In one embodiment, the injection-molded guide comprises an absorbable polymer comprising more than 80% (w / w) lactide residues and also containing trimethylene carbonate residues. In one embodiment, the present disclosure provides an injection-molded guide 3D printed on a mesh comprising an absorbable polymer comprising more than 75% (w / w) lactide residues. In one embodiment, the present disclosure provides an injection-molded guide having an L-shaped cross-section and attached such that the outer edge of the injection-molded guide is flush with the periphery of the mesh. In one aspect, the barrier material and the injection molding guide can both comprise an absorbable polymer. In one aspect, the barrier material and the injection molding guide can both comprise a non-absorbable polymer. In one aspect, the barrier can comprise an absorbable polymer and the injection molding guide can comprise a non-absorbable polymer. In one aspect, the barrier can comprise a non-absorbable polymer and the injection molding guide can comprise an absorbable polymer. In one embodiment, the injection mold guide comprises polypropylene 3D printed onto a barrier material comprising polypropylene. The injection mold guide has an L-shaped cross section and is attached to the barrier material such that the outer edge of the injection mold guide is flush with the outer periphery of the barrier material. In one embodiment, the barrier material comprises a knitted polypropylene mesh.

[0053] In one embodiment, the injection molded guide comprises an absorbable polymer comprising more than 80% (w / w) lactide residues, and the injection molded guide is 3D printed onto a barrier material in the form of a mesh that also comprises an absorbable polymer comprising more than 80% (w / w) lactide residues. Optionally, the injection molded guide has an L-shaped cross section and is attached to the barrier material such that the outer edge of the injection molded guide is flush with the periphery of the mesh. In one embodiment, the injection-molded guide comprises an absorbable polymer comprising about 70% (w / w) to about 90% (w / w) lactide residues and 10% (w / w) to 30% (w / w) trimethylene carbonate residues. The injection-molded guide is optionally 3D printed onto a barrier material in the form of a mesh comprising an absorbable polymer comprising more than 75% (w / w) lactide residues. Optionally, the injection-molded guide has an L-shaped cross-section and is attached to the barrier material such that the outer edge of the injection-molded guide is flush with the periphery of the mesh.

[0054] Polymer Ring The contraceptive device of the present disclosure comprises a polymer ring surrounding the outer periphery of the barrier material. The polymer ring is formed from a polymeric material, sometimes referred to herein as the matrix. Suitable polymers for the matrix include, but are not limited to, polyethylene vinyl acetate, polyurethane, and silicone. Polyurethane polymers used as the matrix include, but are not limited to, polyetherurethane, silicone-polycarbonate-urethane (TSPCU), silicone-polyether-urethane (TSPU), polycarbonate-urethane, and segmented polyurethane. The polyethylene vinyl acetate polymer used as the matrix optionally has a vinyl acetate content of about 15% (w / w) to about 50% (w / w). Polyethylene vinyl acetate polymers that can be used include, but are not limited to, polymers containing about 16% to about 20% vinyl acetate, about 25% to about 35% vinyl acetate, and about 35% to about 50% vinyl acetate. Commercially available polyethylene vinyl acetate polymers that can be used include, but are not limited to, Evatane 18-150 (Arkema, France), Evatane 28-40 (Arkema, France), and Evatane 38-41 (Arkema, France).

[0055] Silicones that can be used to form the ring component can be formed from two-part silicone compositions. In one embodiment, the silicone used to make the ring component is a polysiloxane. Polysiloxanes have the general structure -[Si(R2)-O]-, where R includes, but is not limited to, hydrogen, methyl, ethyl, phenyl, vinyl, trifluoropropyl, or combinations thereof. Polysiloxanes can be linear polymers, branched polymers, or combinations thereof. In one embodiment, two-part liquid silicone rubbers can be used to make the ring component. Two-part silicone compositions can be mixed together and cured or crosslinked using addition curing, condensation curing, or a combination thereof. By selecting the appropriate composition, certain polysiloxanes can be cured at temperatures between about 20°C and about 50°C, commonly referred to as room temperature vulcanization. Certain polysiloxane compositions can be cured at temperatures between about 51°C and about 130°C, commonly referred to as low temperature vulcanization. Certain polysiloxane compositions can be cured above 130°C, commonly referred to as high temperature vulcanization. Components of a two-part composition or mixture may be referred to as thermosetting if they are cured or crosslinked by the application of elevated temperatures. Addition cure compositions may contain platinum catalysts or peroxide compounds to accelerate the cure of certain polysiloxane formulations. Peroxide compounds that can be used include, but are not limited to, dicumyl peroxide, benzoyl peroxide, 2,4-dichlorobenzoyl peroxide, dibenzoyl peroxide, 2,5-dimethyl-2,5-di-t-butylperoxyhexane, or combinations thereof.

[0056] In one embodiment, the first part of the two-part silicone composition that can be used to form the ring structure can contain vinyl groups, hi one embodiment, the second part of the two-part composition can contain hydride groups.

[0057] Silicones that may be used to manufacture the ring components include, but are not limited to, Silastic® Q7-4535, Silastic® Q7-4550, Silastic® Q7-4565, Silastic® Q7-4720, Silastic® Q7-4735, Silastic® Q7-4750, Silastic® Q7-4765, Silastic® Q7-4780, Silastic® C6-135, Silastic® Q7-4780 ... Silastic® C6-150, Silastic® C6-165, Silastic® C6-180, Silastic® C6-350, Silastic® 7-6830, Silastic® Q7-4840, Silastic® Q7-4850, Silastic® Q7-4750, Silastic® 7-6840, Silastic® 7-4860, Silastic® 7-6860, Silastic® 7-4870, Dow Corning® C6-530, Dow Corning® C6-540, Dow Corning® C6-550, Dow Corning® C6-560, Dow Corning® C6-570 and Silbione® Biomedical Silicones (Elkem). In one embodiment, the silicone used is Silastic® Q7-4840. In one embodiment, the silicone used is Silastic® Q7-4850. In one embodiment, the silicone used is LSR M140.

[0058] Copolymers of silicones can also be used. Examples of such polymers include poly(dimethylsiloxane)-containing block copolymers, poly(dimethylsiloxane)-block-poly(ethylene glycol), poly(dimethylsiloxane)-block-poly(vinyl alcohol), poly(dimethylblocksiloxane)-block-poly(acrylic acid), poly(2-hydroxyethyl methacrylate-g-dimethylsiloxane), poly(2,3-dihydroxypropyl methacrylate-g-dimethylsiloxane), poly(dimethylacrylamide)-block-poly(dimethylsiloxane)-block-poly(dimethylacrylamide, poly(dimethylsiloxane)-block-poly(2-(dimethylamino)ethyl acrylate). The silicone used to form the ring structure may be cured to form the elastic ring component. The curing temperature and curing time vary depending on the particular silicone formulation used. For example, the curing temperature can vary from room temperature (15-25°C) to 150°C. In one embodiment, the curing temperature is in the range of 85-140°C. In a preferred embodiment, the curing temperature is in the range of 110-135°C. The curing time varies from a few seconds to several hours, depending on the particular silicone formulation used and the curing temperature employed. In one embodiment, the curing time is in the range of 1 minute to 5 hours. In one embodiment, the curing time is in the range of 1-5 minutes. In one embodiment, the curing time is in the range of 1-5 minutes, and the curing temperature is in the range of 115-140°C.

[0059] The hardness of the ring structure can be measured using a durometer on the standard Shore scale. The ring has a durometer of about Shore A20 to about Shore A80. In one embodiment, the ring durometer is Shore A30 to Shore A60. In another embodiment, the ring durometer is Shore A40 to Shore A50. In another embodiment, the ring durometer is Shore A40 to Shore A46.

[0060] The ring component has an inner diameter and an outer diameter. The inner diameter can be about 35 mm to about 50 mm. In one embodiment, the inner diameter can be about 38 mm to about 45 mm. In one embodiment, the inner diameter can be about 38 mm to about 42 mm. In one embodiment, the ring component has an inner diameter of about 40 mm. In another embodiment, the ring component has an inner diameter of about 35 mm, about 36 mm, about 37 mm, about 38 mm, about 39 mm, about 41 mm, about 42 mm, about 43 mm, about 44 mm, about 45 mm, or about 46 mm. The outer diameter can be about 45 mm to about 70 mm. In one embodiment, the outer diameter can be about 45 mm to about 65 mm. In one embodiment, the outer diameter can be about 52 mm to about 58 mm. In one embodiment, the ring component has an outer diameter of about 55 mm. In another embodiment, the ring component has an outer diameter of about 50 mm, about 51 mm, about 52 mm, about 53 mm, about 54 mm, about 56 mm, about 57 mm, about 58 mm, about 59 mm, or about 60 mm. In one embodiment, the ring component has a radiused outer edge and a radiused inner edge. The radiused outer edge of the ring component can have a radius of about 1.5 mm to about 3.0 mm. In one embodiment, the radiused outer edge of the ring component can have a radius of about 1.8 mm to about 2.2 mm. The radiused inner edge of the ring component can have a radius of about 1.8 mm to about 3.5 mm. In one embodiment, the radiused inner edge of the ring component can have a radius of about 2.2 mm to about 2.8 mm.

[0061] Absorbable and non-absorbable polymers In one embodiment, one or more of the barrier material, injection molded guide, and / or ring structure are formed from a non-absorbable polymer. The term non-absorbable polymer, as used herein, refers to a polymer that is completely or substantially incapable of being broken down and absorbed, either completely or partially, by tissue after introduction into the body. Non-absorbable polymers are also referred to herein as non-absorbable, non-bioabsorbable, non-biostable, non-bioresorbable, non-biodegradable, non-resorbable, non-degradable, insoluble, non-bioerodible, or non-spontaneously soluble. Each of these terms can be used interchangeably.

[0062] For example, one or more non-absorbable polymers may be used to form fibers that can be used to form the barrier material. The barrier material may have a mesh structure, and the mesh may be formed from a non-absorbable polymer. The barrier material may also be a film formed from a non-absorbable polymer. Any non-absorbable polymer capable of forming flexible fibers that can be made into a mesh may be used.

[0063] Examples of non-absorbable polymers include, but are not limited to, polyolefins, polyesters, polyamides, polyurethanes, and fluoropolymers. Polyolefins include, but are not limited to, polyethylene, polypropylene, and copolymers thereof. Non-absorbable polyesters include, but are not limited to, polyethylene terephthalate (PET) and poly-1,4-cyclohexylene-dimethylene terephthalate (PCDT). Non-absorbable polyamides include, but are not limited to, nylon 6, nylon 66, nylon 4, nylon 11, nylon 6,10, and aramids (e.g., Nomex and Kevlar). Non-absorbable polyurethanes include, but are not limited to, Spandex, Lycra, polycarbonate-urethane, silicone-polycarbonate-urethane, polyether-urethane, and silicone-polyether-urethane. Non-absorbable fluoropolymers include, but are not limited to, polytetrafluoroethylene (PTFE), such as those sold under the registered trademark TEFLON™ (EI DuPont de Nemours & Co.), expanded PTFE (ePTFE), and polyvinylidene fluoride. Other non-absorbable polymers suitable for use in the present disclosure include polyetheretherketone (PEEK), polyimide, polyacrylonitrile, acrylonitrile-vinyl acetate copolymer, acrylonitrile-methyl acrylate copolymer, acrylonitrile-vinyl chloride copolymer, acrylonitrile-vinylidene chloride copolymer, regenerated cellulose (e.g., Rayon®), polysulfone, fiberglass, and acrylic polymers. In one embodiment, the non-absorbable polymer is medically acceptable in that it does not cause adverse reactions when placed in a subject's body. In one embodiment, the non-absorbable polymer is polyethylene. In another embodiment, the non-absorbable polymer is polypropylene.

[0064] Any absorbable polymer that can be used in the construction of fibers, meshes, and films can be used to manufacture the barrier material of a contraceptive device. As used herein, polymers that degrade, either completely or partially, after placement in a host can be referred to as absorbable, bioabsorbable, bioresorbable, biodegradable, resorbable, naturally dissolving, non-dissolving, erodible, or bioerodible, soluble, or biosoluble. Each of these terms can be used interchangeably. Absorbable polymers that can be used include polyesters, polycarbonates, polyester-carbonates, polyurethanes, polyamides, polyether-esters, polyorthoesters, polyanhydrides, silk, and combinations thereof.

[0065] In one embodiment, one or more of the barrier material, injection mold guide, and / or ring structure are formed from an absorbable polymer. Suitable absorbable polymers include polymers obtained from the polymerization of at least one monomer selected from the group consisting of glycolide, lactide, ε-caprolactone, trimethylene carbonate, p-dioxanone, 1,5-dioxepan-2-one, and morpholinedione. Polymerization of these monomers can be initiated by an initiator compound having one initiator group, two initiator groups, three initiator groups, four initiator groups, or more than four initiator groups. Initiator groups that can be used include, but are not limited to, hydroxy groups, amine groups, and thiol groups. Initiators having a single initiator group include any compound with a single hydroxyl. Examples of single-hydroxyl alcohols include aliphatic alcohols and aromatic alcohols. Examples of alcohols include, but are not limited to, methanol, octanol, nonanol, decanol, dodecanol, glycolic acid, lactic acid, and methoxypolyethylene glycol. Initiators with a single initiator group include any compound with a single amine. Examples of single amine compounds include aliphatic amines and aromatic amines. Examples of amines include, but are not limited to, triethylamine, ethyldiisopropylamine, dibutylamine, tributylamine, trioctylamine, and 4-(N,N-dimethyl)aminopyridine. Initiators with two initiator groups include diols and diamines. Diols include aliphatic diols and aromatic diols. Examples of diols include, but are not limited to, propanediol, butanediol, hexanediol, dodecanediol, octanediol, decanediol, and polyethylene glycol. Initiators with three functional groups include, but are not limited to, glycerol, trimethylolpropane, triethanolamine, N-2-aminoethyl-1,3-propanediamine, 1,1,1-tris(hydroxymethyl)ethane, and pentaerythritol monostearate.Initiators used to prepare polymers with four or more arms include, but are not limited to, pentaerythritol, glucose, and dipentaerythritol.

[0066] Multiaxial polymers that can be used to make barrier materials for contraceptive devices are described in U.S. Pat. Nos. 6,462,169, 6,794,485, 7,129,319, and 7,070,858, each of which is incorporated herein by reference in its entirety.

[0067] Catalysts that can be used to produce polyester polymers include, but are not limited to, tin-based catalysts, aluminum-based catalysts, zinc-based catalysts, and bismuth-based catalysts. Usable tin-based catalysts include, but are not limited to, stannous 2-ethylhexanoate. Usable aluminum-based catalysts include, but are not limited to, aluminum isopropoxide and triethylaluminum. Usable zinc-based catalysts include, but are not limited to, zinc lactate. Usable bismuth-based catalysts include, but are not limited to, bismuth subsalicylate.

[0068] In another embodiment, the absorbent polymer can be a random copolymer or a block copolymer. Random copolymers can be made by adding two or more different monomers to a reaction mixture and polymerizing the mixture. Block copolymers can be made by first adding one or more monomers and polymerizing them, and then adding a second monomer, different from at least one of the first monomers, to the initial polymer and further polymerizing it. This results in a polymer in which blocks of similar units are linked to blocks of similar units that are different from the first units. In one embodiment, the absorbable polymer may contain 50% (w / w) or more lactide residues. In another embodiment, the absorbable polymer may contain 60% (w / w) or more lactide residues. In another embodiment, the absorbable polymer may contain 70% (w / w) or more lactide residues. In another embodiment, the absorbable polymer may contain 80% (w / w) or more lactide residues. Having 50% (w / w) or more lactide residues. Such absorbable polymers may be referred to herein as lactide polymers or lactide copolymers. The lactide polymer may also contain residues from the polymerization of glycolide, ε-caprolactone, trimethylene carbonate, p-dioxanone, 1,5-dioxepan-2-one, and / or morpholinedione. In one embodiment, the absorbable lactide polymer contains trimethylene carbonate residues. In another embodiment, the lactide polymer contains blocks of trimethylene carbonate residues and blocks of lactide residues. In one embodiment, the lactide polymer can be produced with an 88:12 molar ratio of added lactide to trimethylene carbonate.

[0069] With respect to the preparation of absorbent polymers, in one embodiment, the initiator used in the polymerization is a hydroxyl-based initiator. In one embodiment, the initiator is a diol. In another embodiment, the initiator is 1,3 propanediol. In one embodiment, 1,3 propanediol is used to initiate the polymerization of trimethylene carbonate. In one embodiment, the initiator is a triol. In another embodiment, the initiator is trimethylolpropane. In one embodiment, trimethylolpropane is used to initiate the polymerization of trimethylene carbonate. Once the polymerization is substantially complete, lactide is added to the reaction mixture to produce a triaxial or linear polymer having a trimethylene carbonate-based core terminated with blocks of polylactide.

[0070] In another embodiment, the absorbent polymer comprises polydioxanone residues. In another embodiment, the absorbable polymer comprises polylactic acid, which can be synthesized from L-lactide, D-lactide, D,L-lactide, or combinations thereof.

[0010] Further referring to the absorbable polymer, in one embodiment, the absorbable polymer comprises a copolymer of residues of lactide, trimethylene carbonate (TMC), and ε-caprolactone. In one embodiment, the copolymer is a block copolymer. In one embodiment, the block copolymer has a first block of trimethylene carbonate residues and a second block comprising residues of lactide and ε-caprolactone residues. In one embodiment, the copolymer can be made using at least 70% added lactide monomer based on the total weight of all added monomers. In a preferred embodiment, the added lactide monomer is 70% to 90% of the total weight of all added monomers. In one embodiment, the copolymer can be made using at least 10% added TMC monomer based on the total weight of all added monomers. In a preferred embodiment, the added TMC monomer is 10% to 20% of the total weight of all added monomers. In one embodiment, the copolymer can be produced using at least 3% added ε-caprolactone monomer based on the total weight of all added monomers. In a preferred embodiment, the added ε-caprolactone monomer is 3% to 15% of the total weight of all added monomers. In one embodiment, the initiator used in the polymerization is a hydroxyl-based initiator. In one embodiment, the initiator is a diol. In another embodiment, the initiator is 1,3 propanediol. In one embodiment, 1,3 propanediol is used to initiate the polymerization of trimethylene carbonate. In one embodiment, the initiator is a triol. In another embodiment, the initiator is trimethylolpropane. In one embodiment, trimethylolpropane is used to initiate the polymerization of trimethylene carbonate. Once the polymerization is substantially complete, lactide and ε-caprolactone can be added to the reaction mixture to produce a triaxial or linear polymer having a poly(trimethylene carbonate)-based core terminated with blocks of lactide-co-caprolactone copolymer.

[0071]

[0010] Further referring to the absorbable polymer, in one embodiment, the polymer comprises a copolymer of residues of glycolide, trimethylene carbonate, and ε-caprolactone. In one embodiment, the copolymer is a block copolymer. In one embodiment, the block copolymer has a first block of trimethylene carbonate residues and a second block comprising residues of glycolide and ε-caprolactone. In one embodiment, the copolymer can be made using at least 45% added glycolide monomer based on the total weight of all added monomers. In a preferred embodiment, the added glycolide monomer is 45% to 65% of the total weight of all added monomers. In one embodiment, the copolymer can be made using at least 20% added TMC monomer based on the total weight of all added monomers. In a preferred embodiment, the added TMC monomer is 20% to 30% of the total weight of all added monomers. In one embodiment, the copolymer can be produced using at least 15% added ε-caprolactone monomer based on the total weight of all added monomers. In a preferred embodiment, the added ε-caprolactone monomer is 15% to 30% of the total weight of all added monomers. In one embodiment, the initiator used in the polymerization is a hydroxyl-based initiator. In one embodiment, the initiator is a triol. In another embodiment, the initiator is trimethylolpropane. In one embodiment, trimethylolpropane is used to initiate the polymerization of monomers containing trace amounts of trimethylene carbonate. Once the polymerization is substantially complete, monomers containing trace amounts of glycolide are added to the reaction mixture to produce a triaxial polymer having a trimethylene carbonate-based core terminated with glycolide-based end-grafted homopolymer or copolymer blocks.

[0072] Further referring to the absorbable polymer, in one embodiment, the polymer comprises a copolymer of residues of lactide, trimethylene carbonate, and ε-caprolactone. Optionally, the polymer may comprise glycolide. In one embodiment, the copolymer is a block copolymer. In one embodiment, the block copolymer has a first block of poly(trimethylene carbonate) and a second block comprising residues of lactide. In one embodiment, the copolymer can be made using at least 35% added lactide monomer based on the total weight of all added monomers. In a preferred embodiment, the added lactide monomer is 30% to 45% of the total weight of all added monomers. In one embodiment, the copolymer can be made using at least 10% added TMC monomer based on the total weight of all added monomers. In a preferred embodiment, the added TMC monomer is 10% to 40% of the total weight of all added monomers. In one embodiment, the copolymer can be produced using at least 30% added ε-caprolactone monomer based on the total weight of all added monomers. In a preferred embodiment, the added ε-caprolactone monomer is 30% to 40% of the total weight of all added monomers. In one embodiment, the initiator used in the polymerization is a hydroxyl-based initiator. In one embodiment, the initiator is a triol. In another embodiment, the initiator is trimethylolpropane or triethanolamine. In one embodiment, trimethanolamine is used to initiate the polymerization of monomers containing trace amounts of trimethylene carbonate. Once the polymerization is substantially complete, a trace amount of lactide-containing monomer is added to the reaction mixture to produce a triaxial polymer having a poly(trimethylene carbonate)-based core terminated with lactide-based end-grafted homopolymer or copolymer blocks.

[0073] Absorbable polyesters include polyhydroxyalkanoates. Examples of suitable polyhydroxyalkanoates include, but are not limited to, poly(3-hydroxybutyrate) (PHB), poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), poly(3-hydroxybutyrate-co-4-hydroxybutyrate) (P(3HB-co-4HB)), poly[3-hydroxybutyrate-co-3-hydroxyhexanoate] (P(3HB-co-3HH)), and poly[(R)-4-hydroxybutyrate]poly(4-hydroxybutyrate) (P(4HB)). In one aspect, the barrier construction includes a barrier material and an injection molded guide.

[0074] Bioactive Agents The ring structure may include a bioactive agent. The bioactive agent may be a drug with spermicidal activity, a hormone, an antimicrobial agent, an antibacterial agent, an antifungal agent, an antiprotozoal agent, an antiviral agent, and mixtures thereof. In one embodiment, the ring structure includes a composition that is a spermicide. In another embodiment, the ring structure includes a hormone. In another embodiment, the ring structure includes an antimicrobial agent. In another embodiment, the ring structure includes an antibacterial agent. In another embodiment, the ring structure includes an antifungal agent. In another embodiment, the ring structure includes an antiprotozoal agent. In another embodiment, the ring structure includes an antiviral agent. Optionally, the ring structure includes two of the above agents, for example, a spermicide and a hormone. Agents that exhibit spermicidal activity include, but are not limited to, nonoxynol-9, octoxynol-9, benzalkonium chloride, sodium cholate, copper, ferrous compounds, and combinations of ferrous compounds with ascorbic acid. Ferrous compounds that can be used include ferrous gluconate, ferrous sulfate, ferrous chloride, ferrous fumarate, ferrous lactate, ferrous acetate, ferrous oxalate, ferrous ascorbate, combinations thereof, and hydrates thereof.

[0075] Hormonal agents include, but are not limited to, levonorgestrel, ethinyl estradiol, 17β estradiol, nomegestrol acetate, etonogestrel, progesterone, nestrone, norethisterone enanthate, medroxyprogesterone acetate, and estradiol cypionate. Antiviral agents include, but are not limited to, acyclovir, brivudine, cidofovir, curcumin, dapivirine, desciclovir, 1-docosanol, edoxudine, frameyclovir, fiacitabine, ibacitabine, imiquimod, lamivudine, penciclovir, valacyclovir, valganciclovir, and salts or esters thereof. Curcumin, acyclovir, famciclovir, dapivirine, and valacyclovir are preferred antiviral agents.

[0076] Antifungal agents include, but are not limited to, bifonazole, butoconazole, chlordantoin, chlorphenesin, ciclopirox olamine, clotrimazole, eberconazole, econazole, fluconazole, flutrimazole, isoconazole, itraconazole, ketoconazole, miconazole, nifuroxime, tioconazole, terconazole, undecenoic acid, and salts or esters thereof.

[0077] Antibacterial agents include, but are not limited to, aclosoxacin, amifloxacin, amoxicillin, ampicillin, aspoxicillin, azidocillin, azithromycin, aztreonam, balofloxacin, benzylpenicillin, biapenem, brodimoprim, cefaclor, cefadroxil, cefatrizine, cefcapene, cefdinir, cefetamet, cefinetazole, cefprozil, cefroxadine, ceftibuten, cefuroxime, and cephalexin. , cephalonium, cephaloridine, cefamandole, cefazolin, cephradine, chlorquinaldol, chlortetracycline, cyclacillin, cinoxacin, ciprofloxacin, clarithromycin, clavulanic acid, clindamycin, clofazimine, cloxacillin, danofloxacin, dapsone, demeclocycline, dicloxacillin, difloxacin, doxycycline, enoxacin, enrofloxacin, erythromycin, fleroxacin, flomoxef, flucloxacin Loxacillin, Flumequine, Fosfomycin, Isoniazid, Levofloxacin, Mandelic Acid, Mecillinam, Metronidazole, Minocycline, Mupirocin, Nadifloxacin, Nalidixic Acid, Nifuirtoinol, Nitrofurantoin, Nitroxoline, Norfloxacin, Ofloxacin, Oxytetracycline, Panipenem, Pefloxacin, Phenoxymethylpenicillin, Pipemidic Acid, Piromidic Acid, Pivampicillin, Pivmecillinam, Prurifloxacin Examples of antihistamines include fluflurazine, rufloxacin, sparfloxacin, sulbactam, sulfabenzamide, sulfacytine, sulfamethopyrazine, sulfacetamide, sulfadiazine, sulfadimidine, sulfamethizole, sulfamethoxazole, sulfanilamide, sulfasomidine, sulfathiazole, temafloxacin, tetracycline, tetroxoprim, tinidazole, tosufloxacin, trimethoprim, and salts or esters thereof.

[0078] Antiprotozoal agents include, but are not limited to, acetarsol, azanidazole, chloroquine, metronidazole, nifuratel, nimorazole, omidazole, propenidazole, secnidazole, sinefungin, tenonitrozole, temidazole, tinidazole, and salts or esters thereof.

[0079] The initial loading of the bioactive agent into the ring structure is about 1% (w / w) to about 50% (w / w). In one embodiment, the initial loading of the bioactive agent into the ring structure is about 5% (w / w) to about 30% (w / w). In one embodiment, the initial loading of the bioactive agent into the ring structure is about 5% (w / w) to about 15% (w / w). The contraceptive device, particularly the ring structure, may comprise a ferrous compound and ascorbic acid. In one embodiment, the contraceptive device may comprise ferrous gluconate and ascorbic acid. In one embodiment, the contraceptive device may comprise ferrous gluconate dihydrate and ascorbic acid. In one embodiment, the ferrous gluconate dihydrate dosage is from about 5% (w / w) to about 15% (w / w). In one embodiment, the ferrous gluconate dihydrate dosage is from about 5% (w / w) to about 15% (w / w) and the ascorbic acid dosage is from 4% (w / w) to about 12% (w / w). In one embodiment, the contraceptive device has a molar ratio of ascorbic acid to ferrous gluconate dihydrate greater than 1, greater than 1.5, greater than 1.8, and greater than 2. In one embodiment, the contraceptive device, particularly the ring structure, can contain approximately 400 mg to 1000 mg of ferrous gluconate dihydrate. In one embodiment, the contraceptive device can contain approximately 400 mg to 700 mg of ferrous gluconate dihydrate. In another embodiment, the contraceptive device can contain approximately 450 mg to 550 mg of ferrous gluconate dihydrate. In one embodiment, the contraceptive device can contain approximately 400 mg to 700 mg of ferrous gluconate dihydrate and 250 mg to 500 mg of ascorbic acid. In another embodiment, the contraceptive device can contain approximately 450 mg to 550 mg of ferrous gluconate dihydrate and approximately 350 mg to 450 mg of ascorbic acid.

[0080] The contraceptive device may contain one or more excipients that may function to regulate the pH of the immediate local environment in which the contraceptive device is placed, mediate the acidity of the initial elution from the device, interact with vaginal mucus to increase mucus viscosity, act as an antioxidant, act as a preservative, or modulate the release of biologically active compounds.

[0081] Compounds that regulate the pH of the intermediate local environment include, but are not limited to, acids such as ascorbic acid, oxalic acid, citric acid, tartaric acid, malic acid, maleic acid, lactic acid, and glycolic acid; mixed poly-amino and polycarboxylic acids such as ampholine; amino acids such as glycine, alanine, asparagine, aspartic acid, cysteine, glutamic acid, glutamine, arginine, histidine, isoleucine, leucine, lysine, methionine, phenylalanine, proline, serine, threonine, tryptophan, tyrosine, and valine; and polyacids that release acidic compounds upon degradation, e.g., polyglycosides. Examples of suitable compounds include glycolic acid, carboxyl-containing polyglycolides, poly(lactide-co-glycolide), and poly(glycolide-co-trimethylene carbonate), glycolic acid diblock copolymers such as methoxypolyethylene glycol-polyglycolide, and glycolic acid triblock copolymers such as polyglycolide-polyethylene glycol-polyglycolide. The dosage of the compound capable of adjusting the pH is from about 1% (w / w) to about 20%. In one aspect, the dosage of the compound capable of adjusting the pH is from about 2% (w / w) to about 10%. In one aspect, the dosage of the compound capable of adjusting the pH is from about 2% (w / w) to about 6% (w / w).

[0082] Compounds capable of mediating the acidity of the initial elution solution from the device include, but are not limited to, amino acids such as glycine, alanine, asparagine, aspartic acid, cysteine, glutamic acid, glutamine, arginine, histidine, isoleucine, leucine, lysine, methionine, phenylalanine, proline, serine, threonine, tryptophan, tyrosine, and valine; phosphates such as sodium dihydrogen phosphate, sodium hydrogen phosphate, and trisodium phosphate, and their hydrates; sodium carbonate; sodium acetate; and sodium bicarbonate. The amount of the compound capable of mediating the acidity of the initial elution solution is about 1% (w / w) to about 20%. In one embodiment, the amount of the compound capable of mediating the acidity of the initial elution solution is about 2% (w / w) to about 10% (w / w). In one embodiment, the amount of the compound capable of mediating the acidity of the initial elution solution is about 2% (w / w) to about 6% (w / w). Compounds that act as antioxidants include, but are not limited to, ascorbic acid, sodium ascorbate, calcium ascorbate, magnesium ascorbate, α-tocopherol or vitamin E, glutathione, lipoic acid, uric acid, β-carotene, retinol, ascorbyl palmitate, butylhydroxyanisole, butylhydroxytoluene, dihydroxybenzoic acid, and propyl gallate. The dosage of the antioxidant compound is about 0.5% (w / w) to about 20%. In one embodiment, the dosage of the antioxidant compound is about 1% (w / w) to about 10% (w / w). In one embodiment, the dosage of the compound capable of mediating the acidity of the initial eluate is about 1% (w / w) to about 6% (w / w). Compounds that act as preservatives include, but are not limited to, benzyl alcohol, benzalkonium chloride, butylparaben, chorobaraben, paraben, metacresol, chlorocresol, methylparaben, phenylethyl alcohol, propylparaben, phenol, benzoic acid, sorbic acid, sodium benzoate, and bronidol. The amount of preservative is about 0.05% (w / w) to about 5%. In one embodiment, the amount of preservative is about 0.1% (w / w) to about 2% (w / w). In another embodiment, the amount of preservative is about 0.1% (w / w) to about 1% (w / w). Compounds that can act as release-modifying agents include degradable polymers, sucrose, sodium chloride, and dextrose (glucose). Degradable polymers that can be used include, but are not limited to, polyesters derived from cyclic monomers selected from the group consisting of lactide, glycolide, ε-caprolactone, trimethylene carbonate, and para-dioxanone, and combinations thereof. Furthermore, polyesters can be synthesized to have acid end groups. For example, glycolic acid can be used as an initiator during the synthesis of low molecular weight polymers to provide acid end groups. Polyesters can be formed by ring-opening polymerization of acid-containing hydroxyl initiators, such as glycolic acid, lactic acid, malic acid, tartaric acid, and citric acid, to provide acid ends on the polymer. Polyesters can be processed by grinding the material into a fine powder to produce microparticulates. The particulate material can then be incorporated into the ring formulation prior to the formation of the ring components.

[0083] In one embodiment, the polyester is polyglycolic acid. In one embodiment, the polyester is polyglycolic acid, and the ring-opening polymerization is initiated using glycolic acid. In one embodiment, the polyglycolic acid is micronized to form polyglycolic acid particles. In one embodiment, the polyglycolic acid particles have an average diameter (volume mass) of less than 20 μm, less than 15 μm, less than 10 μm, less than 8 μm, or less than 5 μm. In one embodiment, the polyester is a poly(glycolic acid-co-lactic acid) copolymer. In one embodiment, the polyester is a poly(glycolic acid-co-lactic acid) copolymer, the ring-opening polymerization of which is initiated using glycolic acid. In one embodiment, the poly(glycolic acid-co-lactic acid) copolymer is micronized to form particles of poly(glycolic acid-co-lactic acid) copolymer. In one embodiment, the poly(glycolic acid-co-lactic acid) copolymer particles have an average diameter (volume mass) of less than 20 μm, less than 15 μm, less than 10 μm, less than 8 μm, or less than 5 μm.

[0084] In one embodiment, the release modifier can increase the amount of bioactive agent, in milligrams, released from the contraceptive device into simulated vaginal fluid by more than 1.1-fold over a 7-day sampling period compared to a contraceptive device that does not contain the release modifier. In one embodiment, the release modifier can increase the amount of bioactive agent, in milligrams, released from the contraceptive device into simulated vaginal fluid by more than 1.5-fold over a 7-day sampling period compared to a contraceptive device that does not contain the release modifier. In one embodiment, the release modifier can increase the amount of bioactive agent, in milligrams, released from the contraceptive device into simulated vaginal fluid by more than two-fold over a seven-day sampling period compared to a contraceptive device that does not contain the release modifier. In one embodiment, the release modifier can reduce the amount of bioactive agent, in milligrams, released from the contraceptive device into simulated vaginal fluid by more than 1.1 fold over a 7-day sampling period compared to a contraceptive device that does not contain the release modifier. In one embodiment, the release modifier can reduce the amount of bioactive agent, in milligrams, released from the contraceptive device into simulated vaginal fluid by more than 1.5-fold over a 7-day sampling period compared to a contraceptive device that does not contain the release modifier. In one embodiment, the release modifier can reduce the amount of milligrams of bioactive agent released from the contraceptive device into simulated vaginal fluid by more than two-fold over a seven-day sampling period compared to a contraceptive device that does not contain the release modifier. The dosage of the release modifier is about 1% (w / w) to about 20%. In one embodiment, the dosage of the preservative is about 2% (w / w) to about 10% (w / w). In one embodiment, the dosage of the preservative is about 2% (w / w) to about 6% (w / w).

[0085] One or more active agents or excipients can be incorporated into the ring matrix prior to the formation of the ring structure. These materials can be incorporated by physical mixing, the use of solvents, or by direct incorporation into the polymer above its melting point. In the case of a two-part silicone formulation, the bioactive agent or excipient can be incorporated into one or both of the two parts. In one embodiment, at least one bioactive agent and at least one excipient are added to both parts A and B of the silastic silicone formulation. In one embodiment, the silicone formulation used is Dow's Silastic Q7-4840. In one embodiment, parts A and B of Silastic Q7-4840 contain ferrous gluconate and ascorbic acid. In another embodiment, parts A and B of Silastic Q7-4840 contain ferrous gluconate, ascorbic acid, and a compound capable of adjusting pH. In one embodiment, the compound capable of adjusting pH is glycine. In another embodiment, Parts A and B of Silastic Q7-4840 comprise ferrous gluconate, ascorbic acid, and a compound capable of modulating the release of ferrous ions. In one embodiment, the compound capable of modulating the release of ferrous ions is polyglycolic acid. In one embodiment, Parts A and B of Silastic Q7-4840 comprise ferrous gluconate, ascorbic acid, glycine, and polyglycolic acid.

[0086] As previously mentioned, poly(ethylene-vinyl acetate) (EVA) can be used as the matrix for the ring structure of a contraceptive device. In one embodiment, the EVA can have a vinyl acetate content ranging from 1% to 60%. In a preferred embodiment, the vinyl acetate content is about 2% to 50%. The bioactive agent or excipient can be incorporated into the EVA via a solvent-based process, a hot-melt process, or a combination thereof. In the solvent-based process, the EVA can be dissolved or swollen in a suitable solvent. Suitable solvents include, but are not limited to, toluene, tetrahydrofuran, dichloromethane, methyl ethyl ketone (MEK), or methanol, and combinations thereof, as well as solutions containing one or more of these solvents. One or more bioactive agents and one or more excipients can be added to the formulation. In one embodiment, the formulation can be solvent-cast into a film, and the solvent can be evaporated to produce a material containing EVA, one or more bioactive agents, and one or more excipients. In another embodiment, the solvent can be removed without casting into a film. A composition comprising EVA, one or more bioactive agents, and one or more excipients can be milled or pelletized to produce a particulate composition. This mixture can then be hot-melt extruded to form a material comprising the bioactive agent(s) and the excipient(s). After the material has cooled, the composite mixture can be pelletized. In one embodiment, EVA, one or more bioactive agents, and one or more excipients are physically combined and mixed. This mixture can then be hot-melt extruded to form a material comprising the bioactive agent(s) and the excipient(s). After the material has cooled, the composite mixture can be pelletized. The pelletized material can then be used to injection mold the ring portion of a contraceptive device. In one embodiment, the EVA material can include ferrous gluconate. In another embodiment, the EVA material can include ferrous gluconate and ascorbic acid. In another embodiment, the EVA material can include ferrous gluconate, ascorbic acid, and glycine. In another embodiment, the EVA material may include ferrous gluconate, ascorbic acid, glycine, and polyglycolic acid.

[0087] In the contraceptive devices of the present disclosure, the injection-molded guide may optionally be characterized by one or more of the following exemplary features: (a) non-fibrous, (b) non-porous, (c) uncoated, (d) free of sizing polymer, (e) fixed to the porous barrier material, (f) having a composition that is constant throughout the injection-molded guide, (g) biodegradable, (h) present along or adjacent to the edge of the porous barrier material, (i) extending within the porous barrier material, (j) 3D printed on the porous barrier material, (k) injection molded onto the porous barrier material, (l) not softening at temperatures below 120°C, while the polymer ring is optionally characterized by one or more of the following exemplary features: (a) comprising an elastomeric polymer; (b) comprising a bioactive agent; (c) comprising a ferrous compound; (d) comprising ferrous gluconate or a hydrate thereof; (e) comprising a ferrous compound and ascorbic acid; (g) comprising ferrous gluconate and ascorbic acid.

[0088] manufacturing The contraceptive device of the present disclosure may be manufactured by injection molding the ring component of the device onto a combination of a barrier material and an injection molding guide. The barrier material and the injection molding guide may be fastened together to form a construct. The construct component of the contraceptive device is placed in a mold. The mold is closed, and the ring material is injection molded onto the outer edge portion of the construct component. In one embodiment, the ring component may comprise a silicone containing one or more bioactive agents. In the case of the two-part silicone formulation described herein, parts A and B are mixed immediately before introduction into a heated mold. The mixed silicone is injected into the heated mold and allowed to harden for a period of time. The mold is then opened, and the formed contraceptive device is removed from the mold. The cure rate of the silicone can be controlled by increasing or decreasing the mold temperature. In one embodiment, the injection molding guide is attached to the barrier material. In one embodiment, the flat surface of the construct contacts a support pin in the mold to ensure the barrier construct maintains its proper position and ensures that the injection molding process occurs in a reproducible manner.

[0089] In one aspect, the present disclosure provides a method of forming a contraceptive device, the method comprising: (a) providing a construct, e.g., a construct disclosed herein, comprising a porous barrier material secured to an injection molded guide, the injection molded guide being symmetrical and optionally comprising a plurality of planar surfaces; (b) placing the construct into a heated die; (c) adjusting the position of at least one pin in the die so that the at least one pin contacts a surface of the injection molded guide; (d) blending a two-part thermosetting polymer mixture, e.g., a construct disclosed herein, with a porous barrier material secured to an injection molded guide; (e) applying an elevated temperature, e.g., a temperature above 100°C, e.g., 120-125°C, to the two-part thermosetting polymer mixture to cure the two-part thermosetting polymer mixture in the mold, such that the two-part thermosetting polymer mixture changes from a liquid state to a solid state; and (f) removing the contraceptive device from the die. Optionally, the construct is provided by a method comprising 3D printing an injection-molded guide onto the porous barrier material. Optionally, the construct is provided by a method comprising forming an injection-molded guide by an injection molding process and fixing the injection-molded guide onto the porous barrier material.

[0090] In one aspect, the present disclosure provides a method for forming a contraceptive device, the method comprising the steps of: (a) providing a construct comprising a porous barrier material secured to an injection molding guide, the injection molding guide being symmetrical and optionally comprising a plurality of planar surfaces; (b) placing the construct into a die; (c) adjusting the position of at least one pin within the die so that the at least one pin contacts the planar surface of the injection molding guide; and (d) injecting molten polymer into the die to form a polymer ring, wherein each of the injection molding guide and the porous barrier material is at least partially embedded within the polymer ring. Optionally, the construct is provided by a method comprising 3D printing an injection molded guide onto the porous barrier material. Optionally, the construct is provided by a method comprising forming an injection molded guide by an injection molding process and fixing the injection molded guide onto the porous barrier material.

[0091] In one embodiment, the ring component may comprise an intravaginally biocompatible thermoplastic polymer containing one or more bioactive agents. The thermoplastic material is introduced into the hopper of an injection molding machine. The material is then heated to a temperature at which the thermoplastic material can flow under pressure. The heated thermoplastic material is then injected under pressure into a mold. The mold is cooled and then opened to remove the contraceptive device. In one embodiment, the thermoplastic material used is poly(ethylene-vinyl acetate). In one embodiment, the thermoplastic material is polyurethane.

[0092] In one aspect, the mold is designed to minimize seepage (flash) of injection molding material that protrudes beyond the designed ring structure into the barrier material. The contraceptive device may have a mass of about 4 g to about 8 g. In one embodiment, the mass of the contraceptive device is 4.5 g to 6.5 g. In another embodiment, the mass of the contraceptive device is 5.0 g to 6.0 g. The outer diameter of the contraceptive device may be about 45 mm to about 70 mm. In one embodiment, the outer diameter may be about 45 mm to about 65 mm. In one embodiment, the outer diameter may be about 52 mm to about 58 mm. In one embodiment, the outer diameter of the contraceptive device is about 55 mm. In another embodiment, the outer diameter of the contraceptive device is about 50 mm, about 51 mm, about 52 mm, about 53 mm, about 54 mm, about 56 mm, about 57 mm, about 58 mm, about 59 mm, or about 60 mm. Optionally, the two-dimensional surface area of ​​the elastic ring component is between about 40% and about 55% of the two-dimensional surface area of ​​the contraceptive device. Optionally, the two-dimensional surface area of ​​the exposed barrier component is between about 45% and about 60% of the two-dimensional surface area of ​​the contraceptive device.

[0093] In one embodiment, the contraceptive device comprises a ring component, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide and the porous barrier material are each at least partially embedded within the ring component, the injection-molded guide comprising a plurality of planar surfaces, and the ring component is formed from a polymer, which may be identical to a polymer ring. In one embodiment, the contraceptive device comprises a ring component, a porous barrier material, an injection-molded guide, and one or more bioactive agents, wherein the injection-molded guide and the porous barrier material are each at least partially embedded within the ring component, the injection-molded guide comprising a plurality of planar surfaces, and the ring component is made from a polymer, which may be identical to a polymer ring. In one embodiment, the contraceptive device comprises a ring component, a barrier component, and one or more bioactive agents. In another embodiment, the contraceptive device comprises a ring component, a barrier component, one or more bioactive agents, and one or more excipients. In another embodiment, the contraceptive device comprises a ring component, a barrier component attached to an injection molded guide, and one or more bioactive agents. In another embodiment, the contraceptive device comprises a ring component, a barrier component attached to an injection molded guide, one or more bioactive agents, and one or more excipients. In one embodiment, the injection molded guide portion attached to the barrier material is embedded within the ring component. In another embodiment, the contraceptive device comprises a ring component and a barrier component. In another embodiment, the contraceptive device comprises a ring component, a barrier component, and one or more excipients.

[0094] In one aspect, the contraceptive device comprises a silicone ring component, an absorbable mesh barrier component, ferrous gluconate dihydrate, and ascorbic acid. In one aspect, the absorbable mesh comprises lactide and trimethylene carbonate residues. In one aspect, the contraceptive device comprises a silicone ring component, an absorbable mesh barrier component comprising lactide and trimethylene carbonate residues, ferrous gluconate dihydrate, ascorbic acid, glycine, and polyglycolic acid particles.

[0095] In one aspect, a contraceptive device comprises a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide and the porous barrier material are each at least partially embedded within the polymer ring, and optionally, the injection-molded guide is secured to the porous barrier material. In one aspect, a contraceptive device comprises a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide is entirely embedded within the polymer ring, and the porous barrier material is partially embedded within the polymer ring, and optionally, the injection-molded guide is secured to the porous barrier material. Although a contraceptive device can be made from a construction in which the injection-molded guide is secured to the porous barrier material, it may occur that at some point after the contraceptive device is made, for example during packaging, the injection-molded guide becomes unsecured from the porous barrier material. However, the injection-molded guide remains at least partially embedded, and optionally entirely embedded, within the polymer ring.

[0006] Accordingly, the present disclosure provides a contraceptive device comprising a polymer ring, a porous barrier material, and an injection-molded guide, wherein each of the injection-molded guide and the porous barrier material is at least partially embedded within the polymer ring, and optionally, the injection-molded guide is secured to the porous barrier material. In the above aspects, the injection-molded guide, regardless of whether the injection-molded guide is secured to the porous barrier material, may be characterized as being symmetrical and optionally comprising multiple planar surfaces. For example, in one aspect, the contraceptive device comprises a polymer ring, a porous barrier material, and an injection-molded guide, wherein each of the injection-molded guide and the porous barrier material is at least partially embedded within the polymer ring, and the injection-molded guide is secured to the porous barrier material, and the injection-molded guide is symmetrical and optionally comprises multiple planar surfaces. As another example, in one aspect, a contraceptive device comprises a polymer ring, a porous barrier material, and an injection molded guide, wherein the injection molded guide is entirely embedded within the polymer ring, the porous barrier material is partially embedded within the polymer ring, and the injection molded guide is secured to the porous barrier material, wherein the injection molded guide is symmetrical and optionally comprises a plurality of planar surfaces.As another example, in one aspect, a contraceptive device comprises a polymer ring, a porous barrier material, and an injection molded guide, wherein the injection molded guide and the porous barrier material are each at least partially embedded within the polymer ring, the injection molded guide is not fixed to the porous barrier material, the injection molded guide is symmetrical, and comprises a plurality of planar surfaces.As another example, in one aspect, a contraceptive device comprises a polymer ring, a porous barrier material, and an injection molded guide, wherein the injection molded guide is entirely embedded within the polymer ring, the porous barrier material is partially embedded within the polymer ring, the injection molded guide is not fixed to the porous barrier material, the injection molded guide is symmetrical, and optionally comprises a plurality of planar surfaces.

[0096] In one aspect, the present disclosure provides a contraceptive device including a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide is symmetrical and has a plurality of planar surfaces, the injection-molded guide is fully embedded within the polymer ring, the porous barrier material is partially embedded within the polymer ring, and at least two of the plurality of planar surfaces intersect each other to form a corner. In one aspect, the present disclosure provides a contraceptive device including a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide is symmetrical and has a plurality of planar surfaces, the injection-molded guide is fully embedded within the polymer ring, the porous barrier material is partially embedded within the polymer ring, and the injection-molded guide includes a plurality of corners, each of the plurality of corners being formed by the intersection of two of the plurality of planar surfaces. In one aspect, the present disclosure provides a contraceptive device comprising a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide is symmetrical and has a plurality of planar surfaces, the injection-molded guide is fully embedded within the polymer ring, the porous barrier material is partially embedded within the polymer ring, the injection-molded guide comprises a plurality of corners, each of the plurality of corners being formed by the intersection of two of the plurality of planar surfaces, and a cross-section of the injection-molded guide comprises two shapes selected from an L-shape and a T-shape. In one aspect, the present disclosure provides a contraceptive device including a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide is a symmetrical annular ring with a plurality of planar surfaces, the injection-molded guide is fully embedded within the polymer ring, the porous barrier material is partially embedded within the polymer ring, and at least two of the plurality of planar surfaces intersect each other to form a corner. In one aspect, the present disclosure provides a contraceptive device comprising a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide is symmetrical and has a plurality of planar surfaces, the injection-molded guide is fully embedded within the polymer ring, the porous barrier material is partially embedded within the polymer ring, the injection-molded guide comprises a plurality of corners, each of the plurality of corners being formed by the intersection of two of the plurality of planar surfaces, and a cross-section of the injection-molded guide comprises two shapes that are complementary to each other.

[0097] In one aspect, the present disclosure provides a contraceptive device comprising a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide is fully embedded within the polymer ring, the porous barrier material is partially embedded within the polymer ring, the polymer ring surrounds the porous barrier material, the barrier material is a mesh, and the injection-molded guide is symmetrical. The injection molded guide may be characterized by one or more of the following: (a) being non-fibrous, (b) being non-porous, (c) being uncoated, (d) not containing a sizing polymer, (e) being immobilized on a porous barrier material, (f) having a composition that is constant throughout the injection molded guide, (g) being biodegradable, (h) being present along or adjacent to the edge of the porous barrier material, (i) extending into the porous barrier material, (j) being 3D printed on the porous barrier material, (k) being injection molded on the porous barrier material, or (l) not softening at temperatures below 120°C. In one aspect, the present disclosure provides a contraceptive device comprising a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide is completely embedded within the polymer ring, the porous barrier material is partially embedded within the polymer ring, the polymer ring surrounds the porous barrier material, the barrier material is a mesh, and the injection-molded guide is symmetrical. The polymer ring may be characterized by one or more of the following: (a) comprising an elastic polymer, (b) comprising a bioactive agent, (c) comprising a ferrous compound, (d) comprising ferrous gluconate or a hydrate thereof, (e) comprising a ferrous compound and ascorbic acid, or (g) comprising ferrous gluconate and ascorbic acid. In one aspect, the present disclosure provides a contraceptive device comprising a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide is fully embedded within the polymer ring, the porous barrier material is partially embedded within the polymer ring, the polymer ring surrounds the porous barrier material, the barrier material is a mesh, and the injection-molded guide is symmetrical and comprises a planar surface. The injection molded guide may be characterized by one or more of the following: (a) being non-fibrous, (b) being non-porous, (c) being uncoated, (d) not containing a sizing polymer, (e) being immobilized on a porous barrier material, (f) having a composition that is constant throughout the injection molded guide, (g) being biodegradable, (h) being present along or adjacent to the edge of the porous barrier material, (i) extending into the porous barrier material, (j) being 3D printed on the porous barrier material, (k) being injection molded on the porous barrier material, or (l) not softening at temperatures below 120°C.

[0098] In one aspect, the present disclosure provides a contraceptive device comprising a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide is completely embedded within the polymer ring, the porous barrier material is partially embedded within the polymer ring, the polymer ring surrounds the porous barrier material, the barrier material is a mesh, and the injection-molded guide is symmetrical and comprises a planar surface. The polymer ring may be characterized by one or more of the following: (a) comprising an elastic polymer, (b) comprising a bioactive agent, (c) comprising a ferrous compound, (d) comprising ferrous gluconate or a hydrate thereof, (e) comprising a ferrous compound and ascorbic acid, or (g) comprising ferrous gluconate and ascorbic acid.

[0099] In one aspect, the present disclosure provides a contraceptive device comprising a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide is fully embedded within the polymer ring, the porous barrier material is partially embedded within the polymer ring, the polymer ring surrounds the porous barrier material, the barrier material is a mesh, and the injection-molded guide is symmetrical and comprises a plurality of planar surfaces. The injection molded guide may be characterized by one or more of the following: (a) being non-fibrous, (b) being non-porous, (c) being uncoated, (d) not containing a sizing polymer, (e) being immobilized on a porous barrier material, (f) having a composition that is constant throughout the injection molded guide, (g) being biodegradable, (h) being present along or adjacent to the edge of the porous barrier material, (i) extending into the porous barrier material, (j) being 3D printed on the porous barrier material, (k) being injection molded on the porous barrier material, or (l) not softening at temperatures below 120°C. In one aspect, the present disclosure provides a contraceptive device comprising a polymer ring, a porous barrier material, and an injection-molded guide, wherein the injection-molded guide is completely embedded within the polymer ring, the porous barrier material is partially embedded within the polymer ring, the polymer ring surrounds the porous barrier material, the barrier material is a mesh, the injection-molded guide is symmetrical and comprises multiple planar surfaces. The polymer ring may be characterized by one or more of the following: (a) comprising an elastic polymer, (b) comprising a bioactive agent, (c) comprising a ferrous compound, (d) comprising ferrous gluconate or a hydrate thereof, (e) comprising a ferrous compound and ascorbic acid, or (g) comprising ferrous gluconate and ascorbic acid.

[0100] packaging The contraceptive device can be placed in protective packaging. The protective packaging can protect the contraceptive device from mechanical damage, light, moisture absorption, pathogens, dust, particulate matter, or a combination thereof. The protective packaging can be referred to as primary packaging. Packaging materials used can include high-density polyethylene, polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), polyvinyl chloride (PVC), polycarbonate (PC), polypropylene (PP), high-impact polystyrene (HIPS), Ovantex®, foil, or a combination thereof. The high-density polyethylene packaging can be in the form of a Tyvek® pouch. In one embodiment, the contraceptive device can be packaged in a heat-sealed Tyvek® pouch. In one embodiment, the contraceptive device can be packaged in a heat-sealed foil pouch. In one embodiment, the foil pouch can include aluminum foil. In one embodiment, the contraceptive device can be packaged with a moisture absorber, an oxygen absorber, or both a moisture absorber and an oxygen absorber. In one embodiment, the environment within the packaging of the packaged instrument may contain less than 10% oxygen. In one embodiment, the environment within the packaging of the packaged instrument may contain less than 5% oxygen. In one embodiment, the environment within the packaging of the packaged instrument may contain less than 1% oxygen. In one embodiment, the environment within the packaging of the packaged instrument may contain less than 20% humidity. In one embodiment, the environment within the packaging of the packaged instrument may contain less than 10% humidity. In one embodiment, the environment within the packaging of the packaged instrument may contain less than 1% humidity.

[0101] In one aspect, the packaged contraceptive product may include a desiccant, an oxygen absorber, or both a desiccant and an oxygen absorber. The desiccant or oxygen absorber may be packaged in the primary package along with the contraceptive device. The desiccant or oxygen absorber may be packaged within the foil that houses the contraceptive device within the primary package. In one aspect, the protective packaging containing the device is sealed using a heat sealing process. In one aspect, the protective packaging may comprise a resealable foil pouch. In one aspect, the resealable foil pouch may comprise aluminum foil. The contraceptive device can be packaged within a secondary packaging material. The secondary packaging can contain the contraceptive device packaged within the primary packaging. The secondary packaging can include a cellulosic material. The secondary packaging can include cardboard. The secondary packaging can include a cardboard box. In one aspect, the cardboard box can include a particle board cardboard box. The packaged contraceptive device may include a contraceptive device of the present invention, a primary packaging component, and a secondary packaging component. In one aspect, the packaged contraceptive device further includes a set of instructions. In one aspect, the packaged contraceptive device can include a contraceptive device that includes a silicone ring, a barrier material, ferrous gluconate within the silicone ring, ascorbic acid within the silicone ring, a primary foil package, a secondary cardboard package, and an instruction sheet or prescribing information.

[0102] Contraceptive devices can be sterile. Contraceptive devices can be sterilized by using an alcohol solution, exposing the device to ethylene oxide, ionizing radiation, autoclaving, ultraviolet radiation, or dry heat. Alcohol solutions that can be used include, but are not limited to, methanol, ethanol, isopropanol, and aqueous solutions thereof. Ionizing radiation used includes gamma radiation and electron beam radiation. The dose of ionizing radiation used for sterilization is greater than 20 kGy, greater than 25 kGy, greater than 30 kGy, greater than 35 kGy, or greater than 40 kGy. In a preferred embodiment, the radiation is greater than 25 kGy. For contraceptive devices sterilized using ethylene oxide, the final contraceptive product complies with ISO 10993-7 for residual ethylene oxide and ethylene chlorohydrin levels. In one embodiment, the residual ethylene oxide level is such that the average daily dose of ethylene oxide transferred to the patient is 2 mg / day. In one embodiment, the residual ethylene oxide level is such that the average daily dose of ethylene oxide delivered to the patient is 0.1 mg / day. In another embodiment, the residual ethylene oxide level is such that the maximum ethylene oxide dose delivered to the patient is less than 4 mg in the first 24 hours. In another embodiment, the residual ethylene oxide level is such that the maximum ethylene oxide dose delivered to the patient is less than 60 mg in the first 30 days. In one embodiment, the residual ethylene chlorohydrin level is such that the average daily dose of ethylene chlorohydrin delivered to the patient is 2 mg / day. In one embodiment, the residual ethylene chlorohydrin level is such that the average daily dose of ethylene chlorohydrin delivered to the patient is 0.4 mg / day. In another embodiment, the residual ethylene oxide level is such that the maximum ethylene oxide dose delivered to the patient is less than 9 mg in the first 24 hours. In another embodiment, the residual ethylene oxide level is such that the maximum ethylene oxide dose delivered to the patient is less than 60 mg during the first 30 days.

[0103] The contraceptive device may be in a non-sterile form. In one embodiment, the non-sterile contraceptive device is in a form conforming to U.S.P. <1111> Non-sterile contraceptive devices are2 Non-sterile contraceptive devices may have a total aerobic microbial count (cfu / g or cfu / mL) of 10 1 Non-sterile contraceptive devices may have a total combined yeasts / molds count (cfu / g or cfu / mL) of 10 2 The total aerobic microbial count (cfu / g or cfu / mL) and 1 Non-sterile contraceptive devices may not be contaminated with Pseudomonas aeruginosa, Staphylococcus aureus, or Candida albicans. Contraceptive devices cannot be contaminated with bacterial endotoxins. In one embodiment, contaminated contraceptive devices must have a bacterial endotoxin contamination level of 20 EU per device or less.

[0104] The ring can be inserted into an applicator to facilitate placement of the contraceptive device in the vagina. The applicator can comprise a polymer. Suitable polymers for the applicator are polypropylene, polyethylene, high-density polyethylene, low-density polyethylene, medium-density polyethylene, polyurethane, polystyrene, nylon, polyvinyl chloride, or blends thereof. The applicator can comprise two or more different polymers. In one embodiment, the applicator is made of polypropylene. In one embodiment, the applicator can include a lubricant to reduce friction between the components of the applicator. Suitable lubricants include, but are not limited to, dimethicone, liquid polydimethylsiloxane, fatty acid amides, polyethylene glycol, glycerin, silicone oil, propylene glycol, or combinations thereof. In one embodiment, the applicator further comprises a dye. The dye can impart a color of green, blue, violet, pink, orange, yellow, red, purple, or white. The applicator described in WO2016156403 can be used in the contraceptive device of the present invention and is incorporated herein by reference.

[0105] Prior to use, the contraceptive device must be removed from its primary packaging. The contraceptive device can be inserted into the vagina. The contraceptive device can be inserted while the user is lying down, squatting, or standing with one leg elevated. The contraceptive device is placed within the vagina to act as a physical barrier between the lower vaginal opening and the cervical os. The contraceptive device can be inserted into the vagina on day 1 of the menstrual cycle. The contraceptive device can be inserted into the vagina on days 2-5 of the menstrual cycle. The contraceptive device can be inserted into the vagina using one or more fingers. The contraceptive device can be inserted into the vagina using an applicator. In one aspect, the contraceptive device is biocompatible when assessed by ISO 10993 testing. In one aspect, use of the contraceptive device does not significantly alter the genital bacterial sac when assessed using semi-quantitative culture from the vagina.

[0106] In one embodiment, the contraceptive device is placed in the vagina and maintains the pH of the vagina at 4.6 except for up to 6 hours after intercourse. The contraceptive device releases ferrous ions and / or ferrous salts into the vagina. The ferrous gluconate measured in vaginal fluid before intercourse is greater than 100 μg / g vaginal fluid. In one embodiment, the ferrous gluconate measured in vaginal fluid before intercourse is greater than 500 μg / g vaginal fluid. In another embodiment, the ferrous gluconate measured in vaginal fluid before intercourse is greater than 1000 μg / g vaginal fluid. When placed in simulated vaginal fluid, the contraceptive device releases at least 5 mg of ferrous gluconate per 7 days for at least 35 days. In one embodiment, when placed in simulated vaginal fluid, the contraceptive device releases at least 10 mg of ferrous gluconate per 7 days for at least 35 days. When placed in simulated vaginal fluid, the contraceptive device releases at least 2 mg of ascorbic acid per 7 days for at least 35 days. In one embodiment, when placed in simulated vaginal fluid, the contraceptive device releases at least 5 mg of ascorbic acid per 7 days for at least 35 days.

[0107] kit The present disclosure includes kits comprising the contraceptive medical device disclosed herein housed in a container. The kit optionally further comprises one or more of a lubricant, a spermicidal gel or film, a contraceptive gel and / or an applicator. The kit may further include instructions for use.

[0108] Exemplary Embodiments The present disclosure provides the following numbered embodiments, which are exemplary only and are not intended to be exhaustive of the embodiments provided in the various aspects and embodiments disclosed herein. 1) A contraceptive device comprising a porous barrier material and an injection-molded guide, the injection-molded guide having a plurality of planar surfaces, the injection-molded guide embedded within a polymer ring structure, and optionally, the injection-molded guide and the porous barrier material fixed to each other. 2) The contraceptive device of embodiment 1, wherein the barrier material is a mesh. 3) The contraceptive device of embodiments 1-2, wherein the barrier material is fibrous. 4) A contraceptive device according to any one of embodiments 1 to 3, wherein the barrier material is circular. 5) A contraceptive device according to any one of embodiments 1 to 3, wherein the barrier material is substantially circular. 6) A contraceptive device according to any one of embodiments 1 to 5, wherein the barrier material has a diameter of about 45 mm to about 53 mm. 7) A contraceptive device according to any one of embodiments 1 to 6, wherein the injection-molded guide is non-fibrous. 8) A contraceptive device according to any one of embodiments 1 to 7, wherein the injection-molded guide has three planar surfaces. 9) A contraceptive device according to any one of the preceding embodiments, wherein the injection-molded guide has six planar surfaces. 10) A contraceptive device according to any one of embodiments 1 to 7, wherein the injection-molded guide has eight planar surfaces. 11) A contraceptive device according to any one of the preceding embodiments, wherein the injection-molded guide has a melting point above 120°C. 12) A contraceptive device according to any one of embodiments 1 to 11, wherein the injection-molded guide has a uniform cross-section all around the periphery of the injection-molded guide. 13) A contraceptive device according to any one of the preceding embodiments, wherein the injection-molded guide has a corner formed by two planar surfaces intersecting at an angle of 85-95 degrees. 14) A contraceptive device according to any one of embodiments 1 to 13, wherein the injection-molded guide is uncoated. 15) A contraceptive device according to any one of embodiments 1 to 14, wherein the injection-molded guide does not contain a sizing polymer. 16) A contraceptive device according to any one of embodiments 1 to 15, wherein the injection-molded guide has a single composition throughout the support ring. 17) A contraceptive device according to any one of embodiments 1 to 16, wherein the injection-molded guide is biodegradable. 18) A contraceptive device according to any one of embodiments 1 to 16, wherein the injection-molded guide is non-biodegradable. 19) A contraceptive device according to any one of the preceding embodiments, wherein the injection-molded guide is along the edge of the barrier material. 20) A contraceptive device according to any one of the preceding embodiments, wherein the injection molded guide is adjacent to the edge of the barrier material. 21) A contraceptive device according to any one of embodiments 1 to 20, wherein the injection-molded guide extends into the porous barrier material. 22) A contraceptive device according to any one of embodiments 1 to 21, wherein the injection molded guide is 3D printed onto the barrier material. 23) A contraceptive device according to any one of the preceding embodiments, wherein the injection-molded guide is injection-molded onto the barrier material. 24) A contraceptive device according to any one of embodiments 1 to 23, wherein the ring structure comprises an elastic polymer. 25) A contraceptive device according to any one of embodiments 1 to 24, wherein the ring structure comprises silicone. 26) A contraceptive device according to any one of embodiments 1 to 24, wherein the ring structure comprises poly(ethylene-vinyl acetate). 27) A contraceptive device according to any one of embodiments 1 to 26, further comprising a bioactive agent present within the polymer ring structure. 28) The contraceptive device of embodiments 1-27, further comprising a ferrous compound present within the polymer ring structure. 29) A contraceptive device according to any one of embodiments 1 to 27, further comprising ferrous gluconate or a hydrate thereof present within the polymer ring structure. 30) The contraceptive device of embodiments 1-27, further comprising a ferrous compound and ascorbic acid, each present within the polymer ring structure. 31) A contraceptive device according to any one of embodiments 1 to 27, further comprising ferrous gluconate or a hydrate thereof and ascorbic acid, each present within the polymer ring structure. 32) A kit comprising the contraceptive device described in any one of embodiments 1 to 31, further comprising at least one of a lubricant, a spermicidal gel, a spermicidal film, a contraceptive gel, and an applicator. 33) The kit according to embodiment 32, further comprising a polymeric applicator. 34) The kit according to embodiments 32-33, further comprising a set of instructions for use. 35) A construct for forming a contraceptive device, the construct comprising a porous barrier material secured to an injection mold guide, the injection mold guide comprising a plurality of planar surfaces. 36) The construct of embodiment 35, wherein the barrier material is a mesh. 37) A construct according to embodiments 35-36, wherein the barrier material is fibrous. 38) The construct of embodiments 35-37, wherein the barrier material is circular. 39) The construct of embodiments 35-37, wherein the barrier material is substantially circular. 40) A construct according to embodiments 35 to 39, wherein the diameter or the distance between the two furthest edges is about 45 mm to about 53 mm. 41) A construction according to any one of embodiments 35 to 40, wherein the injection molded guide is non-fibrous. 42) The construction of any one of embodiments 35 to 41, wherein the injection molded guide has a melting point greater than 120°C. 43) A construction according to any one of embodiments 35-42, wherein the injection molded guide has a uniform cross section all around the periphery of the injection molded guide. 44) A construction according to any one of embodiments 35 to 43, wherein the injection molding guide has a corner formed by two planar surfaces intersecting at an angle of 85 to 95 degrees. 45) The construction of any one of embodiments 35-44, wherein the injection molded guide is uncoated. 46) The construction of any one of embodiments 35-45, wherein the injection molded guide does not contain a sizing polymer. 47) The construction of any one of embodiments 35-46, wherein the injection molded guide has a single composition throughout the support ring. 48) A construct according to any one of embodiments 35 to 47, wherein the injection-molded guide is biodegradable. 49) The construction of any one of embodiments 35-48, wherein the injection molding guide is along the edge of the barrier material. 50) The construction of any one of embodiments 35-48, wherein the injection molding guide is located adjacent to the edge of the barrier material. 51) A construction according to any one of embodiments 35 to 50, wherein the injection molded guide extends into the porous barrier material. 52) A construct according to any one of embodiments 35 to 51, wherein the injection molded guide is 3D printed on the barrier material. 53) A construction according to any one of embodiments 35 to 52, wherein the injection molded guide is injection molded onto the barrier material. 54) A method of forming a contraceptive device, comprising: a. providing a construct comprising a porous barrier material secured to an injection molding guide, the injection molding guide comprising a plurality of planar surfaces; b. placing the construct in a die; c. adjusting the position of at least one pin within the die so that the at least one pin contacts a surface of the injection molding guide; and d. injecting molten polymer into the die to form a ring structure that embeds the injection molded guide; A method comprising: 55) The method of embodiment 54, wherein the construct is provided by a method comprising 3D printing an injection molded guide onto the porous barrier material. 56) The construct is a. forming an injection molded guide by an injection molding process; b. securing an injection molding guide over the porous barrier material 55. The method of embodiment 54, provided by a method comprising: 57) The method described in embodiments 54 to 56, wherein the contraceptive device is a contraceptive device described in any of embodiments 1 to 31. 58) The method described in embodiments 54 to 56, wherein the construct is a construct described in any of embodiments 35 to 53.

[0109] Thus, the present disclosure provides, e.g. 1) A contraceptive device comprising a porous barrier material secured to an injection molded guide, the injection molded guide having a plurality of planar surfaces, the injection molded guide being embedded within a polymer ring structure. 2) The contraceptive device of embodiment 1, wherein the barrier material is a mesh. 3) The contraceptive device of embodiment 1, wherein the barrier material is fibrous. 4) The contraceptive device of embodiment 1, wherein the barrier material is circular. 5) A contraceptive device according to embodiment 1, wherein the barrier material is substantially circular. 6) The contraceptive device of embodiment 1, wherein the barrier material has a diameter of about 45 mm to about 53 mm. 7) A contraceptive device as described in embodiment 1, wherein the injection-molded guide is non-fibrous. 8) A contraceptive device as described in embodiment 1, wherein the injection molded guide has a softening point above 120°C. 9) A contraceptive device as described in embodiment 1, wherein the injection-molded guide has a uniform cross-section all around the periphery of the injection-molded guide. 10) A contraceptive device as described in embodiment 1, wherein the injection molded guide has a corner formed by two planar surfaces intersecting at a 90 degree angle. 11) A contraceptive device according to embodiment 1, wherein the injection-molded guide is uncoated. 12) A contraceptive device as described in embodiment 1, wherein the injection molded guide does not contain a sizing polymer. 13) A contraceptive device as described in embodiment 1, wherein the injection molded guide has a single composition throughout the support ring. 14) A contraceptive device as described in embodiment 1, wherein the injection-molded guide is biodegradable. 15) A contraceptive device as described in embodiment 1, wherein the injection molded guide is present along the edge of the barrier material. 16) A contraceptive device as described in embodiment 1, wherein the injection molded guide is located adjacent to the edge of the barrier material. 17) A contraceptive device as described in embodiment 1, wherein the injection molded guide extends into the porous barrier material. 18) The contraceptive device of embodiment 1, wherein the injection molded guide is 3D printed onto the barrier material. 19) A contraceptive device as described in embodiment 1, wherein the injection molded guide is injection molded onto the barrier material. 20) The contraceptive device of embodiment 1, wherein the ring structure comprises an elastic polymer. 21) The contraceptive device of embodiment 1, further comprising a bioactive agent present within the polymer ring structure. 22) The contraceptive device of embodiment 1, further comprising a ferrous compound present within the polymer ring structure. 23) The contraceptive device of embodiment 1, further comprising ferrous gluconate or a hydrate thereof present within the polymer ring structure. 24) The contraceptive device of embodiment 1, further comprising a ferrous compound and ascorbic acid, each present within the polymer ring structure. 25) A kit comprising the contraceptive device of embodiment 1, further comprising at least one of a lubricant, a spermicidal gel, a spermicidal film, a contraceptive gel, and an applicator. 26) A construct for forming a contraceptive device, the construct comprising a porous barrier material secured to an injection mold guide, the injection mold guide comprising a plurality of planar surfaces. 27) The construct of embodiment 26, wherein the barrier material is a mesh. 28) The construct of embodiment 26, wherein the barrier material is fibrous. 29) The construct of embodiment 26, wherein the barrier material is circular. 30) The construct of embodiment 26, wherein the barrier material is substantially circular. 31) The construct of embodiment 26, wherein the barrier material has a diameter of about 45 mm to about 53 mm. 32) The construction of embodiment 26, wherein the injection molded guide is non-fibrous. 33) The construction of embodiment 26, wherein the injection molding guide has a softening point greater than 120°C. 34) The construction of embodiment 26, wherein the injection molded guide has a uniform cross section all around the periphery of the injection molded guide. 35) The construction of embodiment 26, wherein the injection molding guide has a corner formed by two planar surfaces intersecting at a 90 degree angle. 36) The construction of embodiment 26, wherein the injection molded guide is uncoated. 37) The construction of embodiment 26, wherein the injection molded guide does not contain a sizing polymer. 38) The construction of embodiment 26, wherein the injection molded guide has a single composition throughout the support ring. 39) The construct of embodiment 26, wherein the injection-molded guide is biodegradable. 40) The construction of embodiment 26, wherein the injection molding guide is along the edge of the barrier material. 41) The construction of embodiment 26, wherein the injection molded guide is adjacent to the edge of the barrier material. 42) The construction of embodiment 26, wherein the injection molded guide extends into the porous barrier material. 43) The construct of embodiment 26, wherein the injection molded guide is 3D printed on the barrier material. 44) The construction of embodiment 26, wherein the injection molded guide is injection molded onto the barrier material. 45) A method of forming a contraceptive device, comprising: a. providing a construct comprising a porous barrier material secured to an injection molding guide, the injection molding guide comprising a plurality of planar surfaces; b. placing the construct in a die; c. adjusting the position of at least one pin within the die so that the at least one pin contacts a surface of the injection molding guide; and d. injecting molten polymer into the die to form a ring structure that embeds the injection molded guide; A method comprising: 46) The method of embodiment 45, wherein the construct is provided by a method comprising 3D printing an injection molded guide onto the porous barrier material. 47) The construct is a. forming an injection molded guide by an injection molding process; b. securing an injection molding guide over the porous barrier material 47. The method of embodiment 46, provided by a method comprising: 48) The method of embodiment 45, wherein the molten polymer is a mixture of two-part thermosetting polymers.

[0110] As noted elsewhere herein, the present disclosure provides that aspects and embodiments described herein may be combined to describe the contraceptive medical devices and constructs of the present disclosure, or related methods. For example, the present disclosure provides a contraceptive device comprising a porous barrier material and an injection-molded guide, the injection-molded guide having a plurality of planar surfaces, the injection-molded guide embedded in an elastic, bioactive agent-containing polymer ring structure, the injection-molded guide and the porous barrier material being fixed to one another, the barrier material being a circular mesh having a diameter of about 45 mm to about 53 mm, the injection-molded guide having a uniform cross-sectional shape (profile) throughout, the cross-section having at least three planar surfaces, and the injection-molded guide also having a melting point above the temperature used for injection molding. The injection-molded guide can be prepared by 3D printing or injection molding, as two options, and is further characterized by being non-fibrous, uncoated (e.g., no sizing polymer is present in the injection-molded guide), and formed from a single composition rather than a hybrid of two or more different compositions. The injection molded guide lies flush along the outer edge (i.e., periphery) of the circular or substantially circular barrier material, but may optionally be close to the outer edge of the barrier material. If the injection molded guide is 3D printed onto the barrier material, the molten material used to make the injection molded guide may sink into the porous barrier material, resulting in the injection molded guide extending partially into the porous barrier material. In this way, the injection molded guide may become fixed to the porous barrier material. If the injection molded guide is injection molded separately from the porous barrier, the injection molded guide may be fixed to the barrier material by an adhesive or the like.

[0111] definition As used herein, nomenclature for compounds, including organic compounds, can be given using common names, IUPAC, IUBMB, or CAS nomenclature recommendations. When one or more stereochemical features are present, the Cahn-Ingold-Prelog rules for stereochemistry can be used to designate stereochemical priority, E / Z notation, etc. One skilled in the art can readily ascertain the structure of a compound when given a name either by systematic reduction of the compound structure using the naming rules or by commercially available software such as CHEMDRAW™ (Cambridgesoft Corporation, USA). As used in the specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a "functional group," "alkyl," or "residue" includes two or more such functional groups, alkyls, or residues, etc.

[0112] References in this specification and concluding claims to parts by weight of a particular element or component in a composition indicate the mass relationship between that element or component and any other element or component in the composition or article for which that part by weight is stated. Thus, in a compound containing 2 parts by weight of component X and 5 parts by weight of component Y, X and Y are present in a mass ratio of 2:5, and X and Y are present in such ratio regardless of whether the compound contains additional components.

[0113] Weight percent (wt.% or % w / w) of an ingredient is based on the total weight of the formulation or composition in which the ingredient is included, unless otherwise specified.

[0114] As used herein, when a compound is referred to as a monomer or compound, it is understood that this is not to be construed as one molecule or one compound. For example, two monomers generally refers to two different monomers, not two molecules. As used herein, the term "optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event or circumstance occurs and instances where it does not occur. As used herein, the terms "about" and "approximately" mean that the amount or value in question may be a value that will produce the same result or effect as the exact value specified or as described in the claims or teachings of this specification. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and properties are not, and need not be, exact, but may be approximate and / or larger or smaller, as desired, to produce the same result or effect, reflecting tolerances, conversion factors, rounding, measurement error, and the like, as well as other factors known to those skilled in the art. In general, an amount, size, formulation, parameter, or other quantity or characteristic is "about" or "approximately" whether or not expressly stated as such. When "about" is used before a quantitative value, it is understood that the parameter also includes the specific quantitative value itself, unless otherwise specified. As used herein, the term "subject" can be a vertebrate, such as a mammal, fish, bird, reptile, or amphibian. Thus, the subject of the methods disclosed herein can be a human, non-human primate, horse, pig, rabbit, dog, sheep, goat, cow, cat, guinea pig, or rodent. The term does not denote a particular age or sex. Thus, adult and newborn subjects, as well as fetuses, regardless of male or female, are intended to be encompassed. In one aspect, a mammalian subject is a human. A patient refers to a subject suffering from a disease or disorder or seeking contraception. The term "patient" includes human and veterinary subjects. As used herein, the terms "administering" and "administration" refer to any method of providing the disclosed contraceptive compositions to a subject.

[0115] As used herein, the terms "comprise," "include," "comprises," "including," "comprising," "including," "containing," "featuring," "has," "having," or any other variation thereof, are intended to cover an open inclusion. For example, a process, method, article, or apparatus that includes a list of elements is not necessarily limited to only those elements and may include other elements not expressly stated or inherent to such process, method, article, or apparatus. The transitional phrase "consisting of" excludes any element, step, or ingredient not specified in the claim and closes the claim to include materials other than the recited materials, except for impurities ordinarily accompanying the materials. When the phrase "consisting of" appears within a clause in the body of a claim rather than immediately following the preamble, the phrase limits only the elements set forth in that clause and does not exclude other elements from the scope of the claim as a whole. The transitional phrase "consisting essentially of" limits the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel feature(s) of the claimed invention. "Consisting essentially of" occupies a middle ground between a closed claim written in a "consisting of" format and a fully open claim written in a "comprising" format. Appropriate levels of optional additives as defined herein and minor amounts of impurities are not excluded from the composition by the term "consisting essentially of." When a composition, process, structure, or portion of a composition, process, or structure is described herein using open-ended language such as "comprising," unless otherwise specified, the description also includes embodiments that "consist essentially of" or "consist of" an element of the composition, process, or structure, or portion of the composition, process, or structure.

[0116] The articles "a" or "an" are used in connection with various elements and components of the compositions, processes, or structures described herein. This is done merely for convenience and to give a general sense of the composition, process, or structure. Such descriptions encompass "one or at least one" of the element or component. Furthermore, as used herein, the singular articles also encompass plural elements or components, unless it is clear from the specific context that a plurality is excluded. The term "about" means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not, and need not be, exact, but may be approximate and / or larger or smaller, as desired, to reflect tolerances, conversion factors, rounding, measurement error, etc., as well as other factors known to those of ordinary skill in the art. In general, an amount, size, formulation, parameter, or other quantity or characteristic is "about" whether or not it is expressly stated as such.

[0117] The term "or" as used herein is inclusive. That is, the phrase "A or B" means "A, B, or both A and B." More specifically, condition A or B is satisfied when either: A is true (or present) and B is false (or absent), A is false (or absent) and B is true (or present), or A and B are both true (or present). Exclusive "or" is expressed herein with terms such as "either A or B" and "one of A or B."

[0118] Furthermore, ranges described herein include their endpoints unless otherwise specified. Furthermore, when an amount, concentration, or other value or parameter is given as a range, one or more preferred ranges, or a list of upper and lower preferred values, this should be understood to specifically disclose all ranges formed from any pairing of any upper range limit or preferred value with any lower range limit or preferred value, regardless of whether such pairs are separately disclosed. The scope of the present invention is not limited to the specific values ​​recited when defining a range. When a material, method, or machine is described herein with the phrase "known to those skilled in the art," "conventional," or similar phrases, this term is meant to mean that materials, methods, and machines that are prior art at the time of filing this application are encompassed by the description. Materials, methods, and machines that are not currently prior art, but that will be recognized in the art as being suitable for similar purposes, are also encompassed. Unless otherwise specified, all percentages, parts, ratios, etc. amounts are defined by weight.

[0119] All patents, patent applications and references contained herein are expressly incorporated herein by reference in their entirety. Of course, it should be understood that the above relates only to preferred embodiments of the present disclosure, and that numerous modifications or variations may be made without departing from the scope or spirit of the present disclosure as set forth herein. The present disclosure is further illustrated by the examples contained herein, which should not be construed as limiting the scope of the disclosure in any way. On the contrary, it should be clearly understood that various other embodiments, modifications, and equivalents thereof, which may occur to those skilled in the art after reading the description herein, may be employed without departing from the spirit of the present disclosure and / or the scope of the appended claims. [Example]

[0120] Example 1 Synthesis of Lactoprene® 8812 Polymer A multiaxial polymer containing lactide and trimethylene carbonate was synthesized according to U.S. Patent No. 7,048,753. The ratio of lactide to trimethylene carbonate used in the synthesis was 88:12. The polymer was then ground to a smaller particle size.

[0121] Example 2 Extrusion into multifilament yarn-43 The Lactoprene® 8812 polymer was placed in a Novatec polymer dryer and dried at 110°C for approximately 1 hour and 45 minutes. The polymer was then placed in a 43-hole die, with each hole having an inner diameter of 12 mil, and a multifilament yarn was extruded. A spin finish (Lurol® PT-6A spin finish) was applied to the extruded yarn. The extruded yarn was then oriented on a set of godets. The yarn was then reoriented on the godets until the yarn had a denier of 80-100 (g / 9000m) and an elongation of 20-40%.

[0122] Example 3 Extrusion into multifilament yarn-86 The Lactoprene® 8812 polymer was placed in a Novatec polymer dryer and dried at 110°C for approximately 1 hour and 45 minutes. The polymer was then placed in an 86-hole die, with each hole having an inner diameter of 25 mils, and a multifilament yarn was extruded. A spin finish (Lurol® PT-6A spin finish) was applied to the extruded yarn. The extruded yarn was then oriented on a set of godets. The yarn was then reoriented on the godets until the yarn had a denier of 80-100 (g / 9000m) and an elongation of 20-40%.

[0123] Example 4 Extrusion into monofilament yarn The Lactoprene® 8812 polymer was extruded into monofilaments with a final diameter of approximately 1.75 mm.

[0124] Example 5 Knitted mesh Lactide-co-TMC polymer multifilament yarn (Example 2) was wound and warped into a two-ply yarn using an SSM winder and a LIBA GE203A high-speed warper. The two-ply yarn was knitted into a mesh using a LIBA Racop 4-O, 9-gauge, four-reed knitting machine. Reeds 2 and 3 were used for knitting. The knitting machine was set up for 38 courses per inch and a two-reed tricot pattern.

[0125] Example 6 Knitted mesh purification The mesh (Example 5) was cut to a length of approximately 68 cm to provide a mesh panel. The mesh panel was placed into a glass jar. The jar was then filled with isopropyl alcohol (IPA) to within approximately 1 inch of the top of the jar. The jar was sealed and then placed on a jar roller mill set at maximum speed for 10-20 minutes. The mesh panel was removed from the jar. This cleaning process was repeated with fresh IPA. After cleaning, the mesh panel was allowed to air dry for at least 60 minutes. The mesh panel was then dried under full vacuum for 2 hours.

[0126] Example 7 Residual Spin Finish The residual spin finish (Lurol® PT-6A spin finish) in the mesh of the Example 10 construction was analyzed using HPLC analysis. Approximately 800 mg of a sample of Lactoprene 8812 mesh from the Example 10 construction was placed in a 40 mL glass scintillation vial. Approximately 8 mL of an isopropanol solution containing approximately 2.5% (v / v) cyclohexane was added to the sample. The sample was placed on an orbital shaker for 4 hours. The sample was then allowed to settle until most of the fibers had settled. An aliquot of the solution taken from the sample was diluted 1:1 with water. The diluted aliquot was analyzed by HPLC using a C8 column, a water / acetonitrile gradient, and an ELSD detector. The diluted aliquot was analyzed in duplicate; that is, two measurements were performed for each sample. A standard curve was generated using Lurol® PT-6A spin finish. This process was repeated twice, resulting in a total of six measurements for the three constructions. The residual levels of spin finish are shown in Table 1. [Table 1]

[0127] Example 8 Heat setting of knitted mesh The washed mesh panel of Example 6 was placed in a pin frame, and tension was applied to the mesh within the frame. The pin frame containing the mesh panel was placed in an oven set at approximately 145°C for approximately 3 minutes. After cooling, the mesh panel was removed from the pin frame. This process was repeated with several different mesh panels. The heat-cured mesh panels had the following properties (see Table 2). In the table, IV refers to the intrinsic viscosity of the molten mesh. [Table 2]

[0128] Example 9 3D printing of injection molding guides onto barrier mesh A filament of the injection-molded guide material identified in Table 3 was loaded into a 3D printer. The printer's print bed was heated to approximately 100°C, after which the print bed was leveled. The print bed was then cooled to less than approximately 50°C, and a barrier material (mesh) was placed on the print bed. The barrier material was secured to the print bed using adhesive tape. The temperature of the print bed was then increased to approximately 100°C. The injection-molded guide was then printed on top of the barrier material. Following printing, the printed material was held on the print bed for a period of time to anneal the material. The print bed was then allowed to cool naturally, and after the print bed had cooled to a temperature where the barrier material could be safely handled (<50°C), the barrier material was removed from the print bed. Information about the printed barrier construction is provided in Table 3 below. [Table 3]

[0129] Example 10 3D printing of injection molding guides L-shaped injection molded guides were 3D printed onto the lactide / TMC knitted barrier material using Lactoprene® 8812 polymer. The knitting pattern was a tricot-based pattern using 2 ply / 43 count (86 total count) yarn. A filament of Lactoprene® 8812 polymer was loaded into a 3D printer. The printer's print bed was heated to approximately 100°C, after which the print bed was leveled. An injection-molded guide was then printed onto the print bed. Following printing, the printed material was held on the print bed for a period of time to anneal the material. The print bed was then allowed to cool naturally, and after the print bed had cooled to a temperature where the injection-molded guide could be safely handled (<50°C), the injection-molded guide was removed from the print bed. This process was repeated several times. The properties of the printed injection-molded guide are detailed in Table 4 below. In the table, ID refers to the inner diameter of the injection-molded guide, and OD refers to the outer diameter. [Table 4]

[0130] Example 11 Injection molded construction A piece of mesh prepared in Example 5 was cut to the approximate size of the mold. The mesh was inserted into the mold. The mold was closed, and an L-shaped injection molding guide was overmolded onto the mesh using Lactoprene® 8812 polymer. The resulting mesh construct was removed from the mold, and excess mesh on the outer edges of the construct was trimmed from the construct.

[0131] Example 12 Sieving of glycine The glycine was sieved before being incorporated into the silicone. A 200-mesh sieve was added on top of the sieving collection tray. A 100-mesh sieve was then added on top of the 200-mesh sieve. Approximately 600 g of glycine was added on top of the 100-mesh sieve. A cover was placed on the 100-mesh sieve. The combination of sieves was placed in a mechanical sieve shaker. The sieve shaker was run for 10 minutes. The cover and 100-mesh sieve were removed, and the glycine collected on the 200-mesh sieve was placed in a plastic bag. This process was repeated until sufficient sieved glycine was obtained. The plastic bag was then heat-sealed and stored.

[0132] Example 13 Sieving of ferrous gluconate The ferrous gluconate was sieved before being incorporated into the silicone. A 140-mesh sieve was added on top of the sieving collection tray. A 100-mesh sieve was then added on top of the 140-mesh sieve. Approximately 600 g of ferrous gluconate was added on top of the 100-mesh sieve. A cover was placed on the 100-mesh sieve. The sieve combination was placed in a mechanical sieve shaker. The sieve shaker was run for 10 minutes. The cover and 100-mesh sieve were removed, and the ferrous gluconate collected on the 140-mesh sieve was placed in a plastic bag. This process was repeated until sufficient sieved ferrous gluconate was obtained. The plastic bag was then heat-sealed and stored.

[0133] Example 14 Milling and Micronization of Polyglycolic Acid Powder A polyglycolide polymer with terminal carboxylic acid groups (intrinsic viscosity approximately 0.13 dL / g) was ground into a powder using a Thomas Model 4 Wiley Mill. The polyglycolide powder was then micronized using a Fluid Energy Aljet Jet-O-Mizer™ micronizer (Model 0101, 2 mm screen) and a Schenck AccuRate® Tuf-Flex™ metering feeder (Model 102) configured with a half-pitch feed screw for the feeder. The nitrogen pressure was adjusted until the delivery pressure readings on the pusher and grinder nozzles were approximately 120 psi each. The polyglycolide polymer was poured into the feed hopper, and the feed setting was adjusted to 2. The micronizer and feeder were activated, and the polymer passed through the micronizer, micronizing the polymer. The output from the micronizer was collected in a plastic container. After all the polymer had been micronized and collected, the collection container was closed and the equipment was shut down.

[0134] Example 15 The silicone component of the ring was made using medical-grade, two-part, platinum-cure silicone (Silastic® Q7-4840 silicone). Approximately 3 kg of Silastic® Part A was added to the bowl of a Jaygo mixer. Approximately 330 g of ascorbic acid, 441 g of ferrous gluconate, 184 g of glycine, and 184 g of powdered polyglycolide polymer were added to Silastic® Part A. The above materials were mixed for approximately 35 minutes, after which a vacuum was applied to the mixing bowl and the mixture was mixed for an additional 60 minutes. Mixing was stopped for 30 minutes, and the mixture was allowed to naturally degas. The mixture was then slowly mixed for an additional 20 minutes. The vacuum was released, and the mixture was transferred to a plastic bucket. The plastic bucket was then sealed. This process was repeated with approximately 3 kg of Silastic® Part B.

[0135] Example 16 Silastic® Parts A and B, charged with ferrous gluconate and ascorbic acid from Example 15, were placed into a liquid silicone rubber injection molding machine. The barrier material with the 3D-printed injection molding guide was placed into a custom-made stainless steel mold. The top of the mold was brought close to the bottom of the mold, and a clamping force was applied to the mold. Silastic® Parts A and B were mixed in-line and injected into the mold. The Silastic® was cured at approximately 120°C with a clamping pressure of approximately 180 kN for approximately 2-3 minutes. The mold was opened, and the formed device was removed from the mold and allowed to cool naturally to room temperature.

[0136] Example 17 The rings (Example 16) were placed in a Tyvek pouch, which was then heat-sealed. The rings were sterilized using ethylene oxide (ETO). The sterilized rings were then dried under vacuum for approximately 7 days. The rings within the Tyvek pouch were then placed in a labeled foil pouch and heat-sealed.

[0137] Example 18 The properties of the completed contraceptive devices, which underwent ETO sterilization and final packaging, were measured. The contraceptive devices comprise a lactide / TMC polymer knit mesh with ferrous gluconate, ascorbic acid, glycine, and polyglycolide particles as part of the cured silicone ring. The devices also include a 3D-printed lactide / TMC injection molding guide attached to the mesh prior to injection molding of the silicone ring component. The outer diameter of the contraceptive device and the inner diameter of the recone ring component were measured using calipers. Four measurements were performed per ring, and three lots of rings were evaluated. The results are shown in Table 5. [Table 5]

[0138] The mass of the apparatus was measured using a balance, see Table 6. [Table 6]

[0139] The pore size of the mesh was measured as the distance between the interstices. The microscope was set up with the objective lens set at 4x, the microscope light source set to maximum, and an additional external light source focused on the center of the stage. The software system used (Motic Images plus 2.0) was calibrated using a calibration slide. The contraceptive device was placed on the stage so that the barrier material was in the focal path of the microscope. After focusing the image, a 3664 x 2748 pixel image of the barrier material was captured using a digital camera connected to the Motic Images plus 2.0 software. The accuracy was set to 0.01 μm. The pore size was measured as the short width between the interstices of the upper layer of the barrier material. This process was repeated for each mesh within each lot until at least 10 measurements were performed. See Table 7. [Table 7]

[0140] The mesh ring integrity test uses a ball burst strength measurement device to measure the force (N) resulting from displacing the mesh portion of the contraceptive device over a set distance while the silicone ring is constrained. The contraceptive device is placed in a custom-made ball burst frame, and then the top of the frame is closed so that the silicone ring portion of the contraceptive device is firmly held in the frame. The ball attachment was attached to a load cell mounted on an MTS mechanical testing machine. The ball attachment was lowered until it was just above the barrier portion of the contraceptive device. The test was then initiated by pressing the ball attachment against the barrier component of the contraceptive device. The peak load was measured. See Table 8. [Table 8]

[0141] Compression deformation or bending force was measured on the contraceptive devices. Two flat plates were mounted on an MTS Synergie 200 mechanical testing machine. The contraceptive device was placed vertically on the bottom plate, and then the top plate was lowered until it contacted the device and held it in place. The observed load force should be less than 0.25 N. The top plate was then moved downward at a rate of 1 mm / sec for a total distance of 1 inch, initiating the test. The peak load force was measured for each ring from the three lots of rings. See Table 9. [Table 9]

[0142] Example 19 Vertical permeability test The vertical water permeability performance of various knitted meshes and knitted mesh constructions with injection-molded guides was evaluated. In each case, the barrier material was a lactide / TMC copolymer knitted in a tricot pattern. Vertical water permeability performance was tested using a constant head test using ASTM D 4491. See Table 10. [Table 10]

Claims

1. 1. A contraceptive device comprising a polymer ring, a porous barrier material, and an injection molded guide, wherein both the injection molded guide and the porous barrier material are at least partially embedded within the polymer ring.

2. The contraceptive device of claim 1 , wherein the barrier material is a mesh.

3. 10. The contraceptive device of claim 1, wherein the barrier material is fibrous.

4. 10. The contraceptive device of claim 1, wherein the barrier material is circular or substantially circular.

5. The contraceptive device of claim 1 , wherein the barrier material has a diameter of about 40 mm to about 60 mm, for example about 45 mm to about 53 mm.

6. 10. The contraceptive device of claim 1, wherein the injection molded guide is symmetrical.

7. 10. The contraceptive device of claim 1, wherein the injection molded guide comprises a plurality of planar surfaces.

8. 2. The contraceptive device of claim 1, wherein the injection-molded guide comprises a plurality of planar surfaces and has a corner formed by the intersection of two planar surfaces, and optionally the injection-molded guide has a corner formed by two planar surfaces that intersect at an angle, the angle being between 45 degrees and 135 degrees, for example about 90 degrees.

9. 10. The contraceptive device of claim 1, wherein the injection molded guide is at least one of non-fibrous and non-porous.

10. 10. The contraceptive device of claim 1, wherein the injection molded guide is completely embedded within the polymer ring and the porous barrier material is partially embedded within the polymer ring.

11. 10. The contraceptive device of claim 1, wherein the injection molded guide is uncoated and / or does not contain a sizing polymer.

12. 10. The contraceptive device of claim 1, wherein the injection molded guide is secured to the porous barrier material.

13. 10. The contraceptive device of claim 1, wherein the injection molded guide has a composition, the composition being constant throughout the injection molded guide.

14. 10. The contraceptive device of claim 1, wherein the injection molded guide is biodegradable.

15. 10. The contraceptive device of claim 1, wherein the injection molded guide is along an edge of the porous barrier material.

16. 10. The contraceptive device of claim 1, wherein the injection molded guide is adjacent to an edge of the porous barrier material.

17. 10. The contraceptive device of claim 1, wherein the injection molded guide extends into the porous barrier material.

18. 10. The contraceptive device of claim 1, wherein the injection molded guide is 3D printed onto the porous barrier material.

19. 10. The contraceptive device of claim 1, wherein the injection molded guide is injection molded onto the porous barrier material.

20. The contraceptive device of claim 1 , wherein the polymer ring comprises an elastic polymer.

21. 10. The contraceptive device of claim 1, wherein the polymer ring surrounds the porous barrier material.

22. 10. The contraceptive device of claim 1, further comprising a bioactive agent present within the polymer ring.

23. 10. The contraceptive device of claim 1, further comprising a ferrous compound present within said polymer ring.

24. 10. The contraceptive device of claim 1, further comprising ferrous gluconate or a hydrate thereof present within said polymer ring, and optionally further comprising ascorbic acid present within said polymer ring.

25. 10. A kit comprising the contraceptive device of claim 1, further comprising at least one of a lubricant, a spermicidal gel, a spermicidal film, a contraceptive gel, and an applicator.

26. A construct for forming a contraceptive device, the construct comprising a porous barrier material secured to the injection molding guide.

27. 27. The construct of claim 26, wherein the barrier material is a mesh.

28. 27. The construct of claim 26, wherein the barrier material is fibrous.

29. 27. The construct of claim 26, wherein the barrier material is circular or substantially circular.

30. 27. The construct of claim 26, wherein the barrier material has a diameter of about 40 mm to about 60 mm, for example, about 45 mm to about 53 mm.

31. 27. The construction of claim 26, wherein the injection molded guide is symmetrical.

32. 27. The construction of claim 26, wherein the injection molded guide has a uniform cross section all around the periphery of the injection molded guide.

33. 27. The construction of claim 26, wherein the injection mold guide comprises a plurality of planar surfaces.

34. 27. The construction of claim 26, wherein the injection molding guide has a corner formed by the intersection of two planar surfaces, optionally the injection molding guide has a corner formed by two planar surfaces that intersect at an angle, the angle being between about 45 degrees and about 135 degrees, for example about 90 degrees.

35. 27. The construction of claim 26, wherein the injection molded guide is non-fibrous and optionally non-porous.

36. 27. The construction of claim 26, wherein the injection molded guide has a melting point greater than 120°C.

37. 27. The construction of claim 26, wherein the injection molded guide is uncoated.

38. 27. The construction of claim 26, wherein the injection molded guide does not contain a sizing polymer.

39. 27. The construction of claim 26, wherein the injection molded guide has a single composition at each location of the injection molded guide.

40. 27. The construct of claim 26, wherein the injection molded guide is biodegradable.

41. 27. The construction of claim 26, wherein the injection molded guide is along an edge of the porous barrier material.

42. 27. The construction of claim 26, wherein the injection molded guide is proximate an edge of the barrier material.

43. 27. The construction of claim 26, wherein the injection molded guide extends into the porous barrier material.

44. 27. The construct of claim 26, wherein the injection molded guide is 3D printed onto the porous barrier material.

45. 27. The construction of claim 26, wherein the injection molded guide is injection molded onto the porous barrier material.

46. 1. A method of forming a contraceptive device, comprising: a. providing a construct comprising a porous barrier material secured to an injection molding guide; b. placing the construct in a die; c. adjusting the position of at least one pin within the die so that the at least one pin contacts a surface of the injection molding guide; and d. injecting molten polymer into said die to form a polymer ring, wherein said injection molding guide and said porous barrier material are each at least partially embedded within said polymer ring; A method comprising:

47. 47. The method of claim 46, wherein the construct is provided by a method comprising 3D printing the injection molded guide onto the porous barrier material.

48. The construct comprises: a. forming an injection molded guide by an injection molding process; b) securing the injection molding guide onto the porous barrier material; 47. The method of claim 46, provided by a method comprising:

49. 1. A method of forming a contraceptive device, comprising: a. providing a construct comprising a porous barrier material secured to an injection molding guide; b. placing the construct into a heated die; c) adjusting the position of at least one pin within said die so that said at least one pin contacts a surface of said injection molding guide; d. injecting a mixture of two-part thermosetting polymer into the die to form a polymer ring, wherein each of the injection mold guide and the porous barrier material is at least partially embedded within the polymer ring; e. curing the two-part thermosetting polymer mixture in a mold such that the two-part thermosetting polymer mixture changes from a liquid state to a solid state; and f. Removing the molded product from said die; A method comprising:

50. 50. The method of claim 49, wherein the construct is provided by a method comprising 3D printing the injection molded guide onto the porous barrier material.

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