Foam-Like Texture on Implantable Silicone

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Solution Overview

Problem

There is a need for a more optimal surface textured implant that further reduces the potential for capsular contracture, a complication associated with the immune system's response to foreign materials in the body, particularly with smooth surface implants.

Innovation Solution

Methods for creating a foam-like texture on implantable silicone materials involve applying a texturing material lacking a foam-like texture, placing a foam-like material over it, applying pressure for integration, allowing the foam-like texture to set, and removing the foam-like material, which can be achieved using mandrels, film coaters, and metal rings to achieve a biocompatible foam-like textured surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a smooth surface implant is used, then the manufacturing process is simple and the implant is easy to produce, but the capsular contracture rate is high

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcapsular contracture rate

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies porous foam-like materials to create a textured surface on the implant. The porous structure provides a foam-like texture that reduces capsular contracture while maintaining manufacturing feasibility through established foam fabrication processes

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent combines smooth implant materials with foam-like texturing materials to create a composite surface. This composite approach integrates the ease of manufacturing smooth implants with the capsular contracture reduction benefits of textured surfaces

Inventive Principle:

Principle #40Composite materials

2Reliability

If a textured surface implant is used, then the capsular contracture rate is reduced, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvecapsular contracture rateVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs preliminary actions by applying texturing material to a mandrel or film coater before the foam-like material is applied. This preparatory step ensures proper texture formation and integration, reducing the overall manufacturing complexity despite the multi-step process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses an intermediary approach by introducing a texturing material layer between the implant base material and the foam-like material. This intermediary layer facilitates proper integration and texture transfer, simplifying the overall manufacturing process

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If foam-like material is applied directly to implant, then the foam-like texture is achieved quickly, but the integration and texture quality are insufficient

Engineering Contradiction:

Improvetexture application speedVSAvoidtexture quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary texturing material to the mandrel or film coater before applying the foam-like material. This preliminary action ensures proper texture quality and integration while maintaining efficient production through streamlined material application sequences

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent maintains continuity of useful action by applying multiple layers of texturing material and foam-like material in continuous contact. This continuous application process ensures proper integration and texture quality without interrupting the manufacturing flow

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS9155613B2Methods for creating foam-like texture

Publication Date: 2015.10.13 ALLERGAN INC

AI summary

Methods for creating a foam-like texture on an implantable material are provided. More particularly, methods for creating foam-like texture on implantable silicone materials are provided.