US20110046729A1 - Reinforced Prosthetic Implant With Flexible Shell - Google Patents

Reinforced Prosthetic Implant With Flexible Shell Download PDF

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Publication number
US20110046729A1
US20110046729A1 US12/853,003 US85300310A US2011046729A1 US 20110046729 A1 US20110046729 A1 US 20110046729A1 US 85300310 A US85300310 A US 85300310A US 2011046729 A1 US2011046729 A1 US 2011046729A1
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Prior art keywords
shell
silicone elastomer
gel
implant
perimeter region
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Abandoned
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US12/853,003
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English (en)
Inventor
David J. Schuessler
Ahmet Tezel
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Allergan Inc
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Allergan Inc
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Publication date
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Priority to US12/853,003 priority Critical patent/US20110046729A1/en
Assigned to ALLERGAN, INC. reassignment ALLERGAN, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SCHUESSLER, DAVID J., TEZEL, AHMET
Publication of US20110046729A1 publication Critical patent/US20110046729A1/en
Priority to US14/088,163 priority patent/US9486308B2/en
Priority to US15/344,338 priority patent/US10251746B2/en
Priority to US16/282,088 priority patent/US20190175332A1/en
Abandoned legal-status Critical Current

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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
    • A61F2/12—Mammary prostheses and implants
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/14—Macromolecular materials
    • A61L27/18—Macromolecular materials obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/14—Macromolecular materials
    • A61L27/26—Mixtures of macromolecular compounds
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/50—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/04—Rotational or centrifugal casting, i.e. coating the inside of a mould by rotating the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/22—Making multilayered or multicoloured articles
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2240/00—Manufacturing or designing of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof
    • A61F2240/001—Designing or manufacturing processes
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2430/00—Materials or treatment for tissue regeneration
    • A61L2430/04—Materials or treatment for tissue regeneration for mammary reconstruction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2083/00—Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/753—Medical equipment; Accessories therefor
    • B29L2031/7532—Artificial members, protheses

Definitions

  • the present invention relates to soft, fluid-filled prosthetic implants and, more particularly, to a fluid-filled prosthetic implant with a reinforced shell.
  • Implantable prostheses are commonly used to replace or augment body tissue. In the case of breast cancer, it is sometimes necessary to remove some or all of the mammary gland and surrounding tissue that creates a void that can be filled with an implantable prosthesis.
  • the implant serves to support surrounding tissue and to maintain the appearance of the body.
  • the restoration of the normal appearance of the body has an extremely beneficial psychological effect on post-operative patients, eliminating much of the shock and depression that often follows extensive surgical procedures.
  • Implantable prostheses are also used more generally for restoring the normal appearance of soft tissue in various areas of the body, such as the buttocks, chin, calf, etc.
  • Soft implantable prostheses typically include a relatively thin and quite flexible envelope or shell made of vulcanized (cured) silicone elastomer.
  • the shell is filled either with a fluid such as a silicone gel or a normal saline solution. Filling of the shell takes place before or after the shell is inserted through an incision.
  • the present invention pertains to any type of fluid-filled prosthesis, but is especially beneficial for use with gel-filled shells.
  • FIG. 1 is a cross-sectional view through a soft, fluid-filled prosthetic implant having an increased density shell and showing etched information on an exterior label.
  • FIG. 2A is a rear or posterior plan view of a soft, fluid-filled prosthetic implant shell
  • FIG. 2B is a front or anterior plan view of the implant shell of FIG. 2A illustrating a series of drawn concentric bands useful for determining wall thickness across the anterior face;
  • FIG. 3 is a cross-sectional view through the reinforced shell of FIG. 2A showing a reinforced perimeter area
  • FIG. 4 is a detailed cross-sectional view of a fill opening in the shell prior to application of a patch
  • FIG. 5 is a detailed cross-sectional view of the reinforced perimeter area B from FIG. 3 ;
  • FIG. 6 is a cross-sectional view of the reinforced perimeter area of FIG. 5 shown flattened.
  • FIG. 7 is an enlarged portion of FIG. 6 illustrating different thickness layers of the reinforced shell.
  • the present application provides a reinforced prosthetic implant shell.
  • the shell is soft and flexible, and includes a fluid filling of either silicone gel or saline to form a soft prosthetic implant.
  • the most common type of soft prosthesis shown for illustration purposes is for breast reconstruction or augmentation, though prostheses formed in accordance with the teachings herein may be used to restore or augment the appearance of soft tissue in the buttocks, chin, calf, etc.
  • FIG. 1 illustrates an exemplary reinforced breast implant 20 having a flexible outer shell 22 and a fluid 24 filling an internal cavity.
  • a flush patch 26 covers a manufacturing hole, though other configurations such as a fluid-adjustment valve or other patch may be substituted.
  • the fluid 24 may be a gel, such as a silicone gel, saline, or other suitable fluid filler.
  • the breast implant 20 may be reinforced in a number of ways, the goal being a stronger implant that resists rupture, while also being more cosmetically acceptable.
  • the implants disclosed herein are designed to be 20% more rupture-resistant than previous shells of this type, as measured by an ISO static rupture test.
  • the shells have been tested to be 20% stronger than prior shells based on the major shell strength parameters of break force, tear strength and elongation.
  • the shells are about 20% softer from durometer testing, and have about a 50% reduction in gel permeability according to the ASTM silicone disk method.
  • These are performance values based on an Allergan brand Style 15 shell having a volume size of 304 cc, though the results are considered representative for shells of similar styles and sizes. Further details on the specific tests used will be given below.
  • the implants may be reinforced generally using several methods: reinforcement of the shell wall, non-homogeneous gel-filling, or both. There are a number of ways disclosed to reinforce the shell wall, and also to selectively fill certain areas with different gels, and it should be understood that the application contemplates the combination of any of these possibilities.
  • the shells are formed of silicone and have a generally rounded frontal elevational shape with an oval- or teardrop-shaped (hereinafter, “generally oval”) central vertical cross-section.
  • the shells have an anterior or first face opposed to a posterior or second face separated by a perimeter line. The radius of curvature of the shell as seen in vertical section is smallest at the perimeter line.
  • the shells may have either a smooth or textured outer shell.
  • the shell can be circular, oval, crescent-shaped or other suitable shapes. It can be formed of silicone rubber, a laminate of various forms of silicone, silicone copolymers, polyurethane, and various other elastomers in various combinations.
  • the reinforced shells disclosed herein can have an all barrier shell with a reinforced (RF) perimeter to produce, e.g., round gel-filled breast implants with, e.g., a smooth but matte finish exterior surface. This compares with existing smooth round breast implants currently on the market which have the gel-diffusion inhibiting barrier layer sandwiched between standard silicone layers that comprise the shell and have a glossy exterior surface finish.
  • the shell may be filled with either responsive gel (Allergan TruForm I) or so-called, “Soft Touch” gel (Allergan TruForm II).
  • the shells can be silicone gel-filled, packaged and sterilized ready for physician use.
  • a manufacturing method can be a rotational casting process. This process includes making the shell in two castings.
  • the shells disclosed herein may be reinforced by adding silicone material around the perimeter region relative to the first or second faces.
  • at least a portion of the perimeter region has a shell wall thickness greater than the average shell wall thickness of either the anterior face or the posterior face.
  • the added material at the perimeter region strengthens that area in which a large percentage of implant ruptures occur.
  • the reinforced perimeter also may help prevent the implant from collapsing or folding, thereby reducing the possibility of undesirable rippling or wrinkling visible through the patient's skin.
  • the remainder of the shell will desirably have a nominal wall thickness to retain the overall softness and supple feel of the implant.
  • FIG. 2A is a rear or posterior plan view of the soft prosthetic implant shell 22
  • FIG. 3 is a horizontal cross-section through the shell with the posterior face down and the anterior face up.
  • the shell 22 is axi-symmetric about central axis 28 , so the vertical cross-section will be the same.
  • the shell 22 may have a contour, similar to a teardrop in side profile, with a larger lower lobe and thinner upper portion.
  • the particular wall thickening described for the axi-symmetric shell shown may be applied to a non axi-symmetric shell, or the increased wall thickness may be non-uniform around the shell perimeter as needed.
  • FIGS. 2A and 3 show the manufacturing hole 30 of the shell 22 , without the flush patch 26 described above.
  • the manufacturing hole 30 defines a beveled edge with a smaller outer rim 32 opening to a larger inner rim 34 . This shape helps mate with the flush patch 26 for a smoother final assembly.
  • FIG. 5 is a detailed cross-sectional view of the reinforced perimeter 40 from area B shown in FIG. 3
  • FIG. 6 is the same region shown flattened.
  • the shell 22 may be segregated into three discrete geometric bands or areas, A, B and C, perpendicular to the central axis 28 as seen in FIG. 3 .
  • Area A comprises a posterior band, area B a middle band, and area C an anterior band.
  • the shell 22 as seen in cross-section in FIG. 3 extends from the lower manufacturing hole 30 to an upper apex 42 (in this embodiment, the uppermost point on the anterior face).
  • the shell 22 is outwardly convex in this view, and has a maximum radius about the central axis 28 along a radius midpoint plane MP at a perimeter P, as seen in FIGS. 5 and 6 .
  • the radius midpoint plane MP includes the perimeter P or generatrix at which a line TL tangent to the exterior curvature of the shell 22 parallels the central axis 28 .
  • the perimeter P (or radius) of the shell thus defines the widest radial plane, and forms a line around the shell at the outermost diameter of the device as it sits posterior side down on a flat surface. This perimeter line separates the anterior face from the posterior face.
  • FIG. 2B shows the anterior face circumscribed by the perimeter P.
  • the anterior face is the top portion of the shell (with the apex 42 as its center) extending down to the extreme outer edge or perimeter line P, while the posterior face extends around the bottom portion of the shell below the perimeter line.
  • a perimeter region can be defined as a region (as opposed to a line) where the anterior face and posterior face meet and containing portions of both the anterior face and the posterior face.
  • the present invention provides a reinforced or thickened wall portion in the perimeter region with a longitudinal axis coincident with the central axis 28 of the perimeter P.
  • Posterior area A extends from the manufacturing hole 30 to a first lateral plane P 1 spaced X mm axially below or in the posterior direction from the radius midpoint plane MP.
  • Anterior area C extends from the shell apex 42 to a second lateral plane P 2 spaced Y mm axially above or in the anterior direction from the radius midpoint plane MP.
  • middle area B extends between areas A and C.
  • the distance X ranges between about 2-6 mm
  • the distance Y ranges between about 7-20 mm. For instance, the distance X is about 5 mm and the distance Y is about 10 mm.
  • the wall thickness in posterior area A is between about 0.013-0.040 in (0.33-1.02 mm), as measured at points spaced about 3-5 mm from the inner edge of the shell hole 30 .
  • the wall thickness in middle or reinforced area B is between about 0.020-0.060 in (0.51-1.52 mm), as measured at various points from first lateral plane P 1 to the second lateral plane P 2 .
  • the wall thickness in anterior area C is between about 0.013-0.040 in (0.33-1.02 mm), as measured at points located from about halfway between the midpoint plane MP and the apex 42 to within about 15 mm of the apex.
  • the nominal (non-reinforced) shell wall thickness is at least 0.254 mm (0.010 inches), and desirably about 0.456 mm (0.018 inches).
  • the implant shell may be made by dip-forming, spray-forming, or rotational molding.
  • the exterior may be smooth or textured.
  • FIG. 6 shows that a point of maximum thickness 44 desirably exists just above, or in the anterior direction, from the midpoint plane MP.
  • the wall thickness gradually increases from both the first and second lateral planes P 1 , P 2 toward the midpoint plane MP.
  • the linear distance (X+Y) between the first and second lateral planes P 1 , P 2 is between about 15-17 mm, and potentially up to about 24 mm.
  • the thickness increases symmetrically therebetween so that the point of maximum thickness 44 is equidistant from either lateral plane.
  • the central portion of the region of increased thickness is offset in an anterior direction from the midpoint plane MP.
  • other configurations are possible.
  • the region of increased thickness may extend outside of the middle area B into areas A or C, as is shown in FIG. 6 .
  • Other configurations are contemplated, and the placement of the region of increased thickness as well as the point of maximum thickness 44 may be altered depending on the size or shape of the particular shell, the shell material, the nominal thickness of the shell in the other areas, and other factors.
  • the region of increased thickness desirably circumscribes the perimeter evenly, it may vary around the shell, and may even be omitted in some areas.
  • FIG. 7 is an enlarged portion of FIG. 6 illustrating different thickness layers of the reinforced shell. It is important to recognize that not all of the increased thickness in the perimeter region of the shell is deliberately formed, and some occurs as a normal consequence of the preferred rotational molding process.
  • the reinforced shell is desirably made by rotational molding (as opposed to mandrel dipping).
  • the implant shells of the present invention are desirably formed using a rotational molding system, such as disclosed in U.S. Pat. Nos. 6,602,452 and 7,165,964, and U.S. Patent Publication No 2008-0181981, all to Schuessler, which are expressly incorporated herein by this reference.
  • Schuessler discloses a rotational molding machine for forming medical articles, in particular for molding silicone elastomer shells for breast implants.
  • One method of making the reinforced shell comprises introducing a small amount of liquid silicone in a rotational mold cavity and rotating the mold about only one axis (typically while heating). This creates a band of silicone within the mold around the perimeter location. Next more (or most) of the liquid silicone is added into the mold cavity and the mold is then rotated about two or more axes (and also typically while heating) to thereby form the entire shell—now with a reinforced perimeter band going all the way around the shell.
  • the molded shell is then cured, either before or with the application of a patch over the mold hole.
  • a silicone gel is then injected into the shell interior.
  • a first or outer layer 50 represents a first amount of shell wall material formed into a peripheral band.
  • a second or inner layer 52 and a third, intermediate layer 54 represents a second amount of shell wall material forming the majority of the shell 22 . That is, the preferred process for forming the shell 22 comprises first rotational casting the peripheral band 50 around a mold cavity perimeter region, and then casting the entire shell including simultaneously casting the second and third layers 52 , 54 within the peripheral band.
  • the peripheral band 50 extends an axial distance (when flattened) between posterior and anterior borders B 1 , B 2 .
  • the distance between the first and second lateral planes P 1 , P 2 is between about 15-17 mm, and potentially up to 24 mm.
  • the axial distance the posterior and anterior borders B 1 , B 2 of the peripheral band 50 is less than that, and preferably ranges between about 10-20 mm.
  • the rest of the thickened shell wall, represented by the intermediate layer 54 is a consequence of the rotational molding process and is formed in all shells made in this manner. Stated another way, only the first or outer layer 50 comprises material added to a conventional rotationally molded shell.
  • the region of increased thickness that extends between the first and second lateral planes P 1 , P 2 is not entirely a “reinforced portion,” in that the intermediate layer 54 is present in prior shells.
  • the reader will understand that illustration of the intermediate layer 54 is for convenience and comparison with the other two layers 50 , 52 , though the second casting of silicone material will build up smoothly against the interior of the mold cavity and preformed peripheral band 50 . Therefore, the extra material that accumulates in the peripheral region cannot be pinpointed to the inside or outside of that casting, and the depiction of the intermediate layer 54 on the outside is arbitrary in that respect.
  • the reinforced portion is limited to the area of the shell that is less than about 0.5 inches (about 12.7 mm) from the perimeter (line at the midplane MP).
  • a methodology of measuring this thickness and assessing shells is important to be able to quantify where the reinforced area actually starts.
  • a reinforced region will be thicker than other regions, and the thickness of any one region will be determined as an average. It will be understood that, as a practical matter, only a limited number of single point measurements may be made to determine the average thickness of any one region of the implant.
  • One method used herein is to divide the shell anterior face into concentric bands centered on the central axis 28 , determine the average thickness of each band, determine the proportion of each band relative to the total anterior face surface area, and then arrive at a total average thickness for the whole anterior face as well as the reinforced region.
  • First shell thickness measurements are taken from the perimeter P and every 5 mm along a line (termed a spline) on the shell surface to the apex 42 . Repeat at 90 degree intervals around the shell for a total of 4 splines or sets of thickness measurements. Each 5 mm interval along the splines then determines a band A 5 , A 10 , etc. ( FIG. 2B ) which in turn locates eight thickness measurements around its borders. For instance, FIG. 2B shows eight dots located at the eight spline corners for the second largest band A 10 , which is between 5-10 mm onto the anterior face from the perimeter P. Thickness measurements at these eight points are taken and their average is then an approximation of the average thickness of the thickness of whole band A 10 .
  • each band (A 5 , A 10 , etc.) to the total area of the anterior face depends on the size or diameter of the shell 22 which will determine the area of each band. Given a certain shell diameter, and assuming the anterior shell surface is flat, a weighted average calculation for each band's contribution to the whole shell can be done. Exemplary shell surface area calculations are shown in the table below for a shell having a diameter of 100 mm.
  • the present application desirably provides shells 22 in which bands A 5 and A 10 are reinforced, or have a thickness greater than the average anterior thickness, and the bands farther than 10 mm away from the perimeter P (i.e., A 15 , A 20 , etc.) have an average thickness less than the average anterior thickness, and are thus not part of the reinforced region.
  • the reinformed perimetric region does not extend farther than 10 mm from the perimeter line P onto the anterior face.
  • a larger reinforced region may be provided, such as one which extends at least 50 mm from the perimetric line P, or substantially the entire anterior face.
  • These exemplary dimensions for the reinforced region may be mirrored onto the posterior face, or may be limited only to the anterior face.
  • Another more accurate measurement technique includes destruction of a sample of shells and more data points. For instance, the measured band increments will be approximately every 0.050 inches, or approximately 1 mm instead of 5 mm. Also, the number of splines will be increased from four to eight, or about every 45° around the shell.
  • One useful method is to sample more shells using the non-destructive fewer-point measurement model as a screening tool. Once sufficient data is gathered, a correlation study may be performed between the original non-destructive tests and the finer destructive model to validate the non-destructive model.
  • a preferred rotational molding techniques results in a relatively smooth transition between the perimetric reinforced region and the anterior and posterior faces.
  • the transition between the posterior and anterior faces may not be smooth, or the transition between the reinforced perimeter and just the anterior face may not be smooth.
  • One example of a non-smooth transition is a step between the regions which may be formed by placing an insert into the rotational mold. Or, the mold itself may be provided with a corner or other such discontinuity to result in a step or corner on the exterior of the shell.
  • Prototypes of the reinforced shells have been made with rotational molding with different levels of silicone material in the preferred two step casting process; a first casting step to create a band of silicone within the mold around the perimeter, and a second casting step to form the entire shell.
  • a first casting step to create a band of silicone within the mold around the perimeter
  • a second casting step to form the entire shell.
  • 76 different breast implant shells were formed from 76 different silicone first and second dispersion fills, consisting of five separate series of castings of different profiles over a range of mold sizes, tabulated below.
  • the mold diameters ranged from 9.0 to 17.5 cm, though not all the test series included all of the diameters.
  • One example of the two-step casting process as detailed in the first row in Table III below includes a first casting of 4.6 g of 36.3% solid silicone/xylene dispersion.
  • the operator introduces the first casting material into the rotational casting mold and spins the mold about its central axis so that the first casting material accumulates around the perimeter.
  • the operator then introduces 24.7 g of the second casting material (36.3% dispersion) into the mold and spins the mold about multiple axes so that the second casting material substantially evenly covers the inside of the mold and the band of first casting material.
  • Both casting steps are desirably done in conjunction with heating and solvent gasses are vented throughout.
  • the first casting may or may not be cured prior to performance of the second casting.
  • first and second dispersion fills presume a silicone dispersion having 36.3% solids. That is, the dispersion includes 36.3% by mass solid silicone particles and the rest a solvent, typically xylene. If the dispersion varies, the amounts for the first and second castings will also vary to ensure formation of the same thickness shell wall.
  • the five tables show preferred results for the different mold profiles over a range of diameters. That is, a conventional shell is typically formed with a single dispersion fill the amount of which is shown in column 3 . It should be noted that the dispersion for the target single casting is slightly different, 35% rather than 36.3%.
  • the last column indicates the ratio in percent of the first reinforcement cast to the second shell cast.
  • the reinforced prosthetic implant may also be characterized by alterations in gel filler cohesiveness. Implants having fillers of varying density are known in the art. For example, Allergan's Style 510 Dual Gel breast implant contains two different cohesive gels. The posterior of the implant is made from standard cohesive gel, while the anterior is made from a high cohesive gel. This configuration provides superior projection and support, emphasizing the nipple/areola area of the implant.
  • one alternative to make the implant is to cast a ring of soft gel (less cohesive) under the radially reinforced area so that the feel of that area is more cosmetically acceptable.
  • the soft filler counterbalances the relatively more rigid perimeter area.
  • the remainder of the shell is filled with a firmer gel (more cohesive) that will more effectively maintain the implant shape than the softer gel.
  • a further alternative technique to make the implant is to reinforce the radius or perimeter area by using a ring of firmer gel only around the perimeter, which will better resist deformation. The rest of the shell is filled with a softer gel. This technique can be done with or without also reinforcing the shell perimeter.
  • the implant desirably utilizes a single layer all barrier shell (“ABS”).
  • ABS is made of silicone in which about 15% of the molecules have phenyl substituents.
  • the non-ABS layers have only about 5% phenyl substituents.
  • the shell made of a single barrier layer.
  • the barrier layer is formed of a homogeneous silicone elastomer capable of sterically retarding permeation of the silicone gel through the shell and having a bleed rate that is less than about 40% of the bleed rate of current shells which use a sandwiched construction with an internal barrier layer.
  • the barrier layer shell is made of a material that exhibits a wet strength that is comparable to or greater than current shells.
  • the silicone elastomer may be a dimethyl polysiloxane, and the substituted chemical group is a diphenyl group with a minimum mole percent of at least about 10%, for example, at least about 13%.
  • Such materials have been described in Schuessler et al., U.S. Patent Publication No. 2009-0030515, the entire disclosure of which is expressly incorporated herein by this reference.
  • a reinforced shell breast implant disclosed herein may be implanted in any number of well-known methods. For instance, a number of possible incisions used by surgeons include an inframammary incision, a periareolar incision, and a transaxillary incision.
  • a resilient sizer may be used to determine the size (and possibly shape) of the appropriate implant, which is then selected and prepared for implant. The surgeon collapses the breast implant, sometimes with the assistance of a tool such as a funnel, and delivers the implant through the chosen incision. Once inserted and oriented properly, the implants resiliently expand back to their original forms without much if any manipulation by the surgeon. At this point, the surgeon can finally observe and evaluate whether the size and shape of the selected implant is appropriate for the patient.

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  • Health & Medical Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Transplantation (AREA)
  • Veterinary Medicine (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • Medicinal Chemistry (AREA)
  • Epidemiology (AREA)
  • Dermatology (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Cardiology (AREA)
  • Biomedical Technology (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Vascular Medicine (AREA)
  • Prostheses (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
US12/853,003 2009-08-18 2010-08-09 Reinforced Prosthetic Implant With Flexible Shell Abandoned US20110046729A1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
US12/853,003 US20110046729A1 (en) 2009-08-18 2010-08-09 Reinforced Prosthetic Implant With Flexible Shell
US14/088,163 US9486308B2 (en) 2009-08-18 2013-11-22 Method of making a reinforced prosthetic implant with flexible shell
US15/344,338 US10251746B2 (en) 2009-08-18 2016-11-04 Method of making reinforcing prosthetic implant with flexible shell
US16/282,088 US20190175332A1 (en) 2009-08-18 2019-02-21 Reinforced prosthetic implant with flexible shell

Applications Claiming Priority (2)

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US23475109P 2009-08-18 2009-08-18
US12/853,003 US20110046729A1 (en) 2009-08-18 2010-08-09 Reinforced Prosthetic Implant With Flexible Shell

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US20110046729A1 true US20110046729A1 (en) 2011-02-24

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US12/853,003 Abandoned US20110046729A1 (en) 2009-08-18 2010-08-09 Reinforced Prosthetic Implant With Flexible Shell
US14/088,163 Active 2031-08-29 US9486308B2 (en) 2009-08-18 2013-11-22 Method of making a reinforced prosthetic implant with flexible shell
US15/344,338 Active 2030-11-19 US10251746B2 (en) 2009-08-18 2016-11-04 Method of making reinforcing prosthetic implant with flexible shell
US16/282,088 Abandoned US20190175332A1 (en) 2009-08-18 2019-02-21 Reinforced prosthetic implant with flexible shell

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US14/088,163 Active 2031-08-29 US9486308B2 (en) 2009-08-18 2013-11-22 Method of making a reinforced prosthetic implant with flexible shell
US15/344,338 Active 2030-11-19 US10251746B2 (en) 2009-08-18 2016-11-04 Method of making reinforcing prosthetic implant with flexible shell
US16/282,088 Abandoned US20190175332A1 (en) 2009-08-18 2019-02-21 Reinforced prosthetic implant with flexible shell

Country Status (7)

Country Link
US (4) US20110046729A1 (fr)
EP (1) EP2467175B1 (fr)
AR (1) AR081086A1 (fr)
AU (1) AU2010284503A1 (fr)
CA (1) CA2771613A1 (fr)
ES (1) ES2537659T3 (fr)
WO (1) WO2011022235A2 (fr)

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US20120197393A1 (en) * 2009-10-16 2012-08-02 Yu Won-Seok Silicone artificial breast prosthesis which minimizes stress concentration, and production method therefor
EP2724688A2 (fr) * 2011-06-23 2014-04-30 Won-Seok Yu Implant mammaire en silicone qui minimise la concentration de contraintes et son procédé de fabrication
US9408692B2 (en) 2010-09-28 2016-08-09 Won Seok Yu Round or anatomical type silicone prosthesis having shell with enhanced durability and method for manufacturing same
US20160250758A1 (en) * 2013-10-22 2016-09-01 Cornell University Soft robot device and related fabrication methods
US20170020620A1 (en) * 2015-07-21 2017-01-26 Jason Leedy Breast implant sizer assembly and method
US9901438B2 (en) 2012-09-17 2018-02-27 Jamm Technologies, Inc. Method of manufacturing breast implants with integrated transponders
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US20180243569A1 (en) * 2017-02-28 2018-08-30 Boston Scientific Neuromodulation Corporation Implantable Medical Device with a Silicone Housing
RU2671587C1 (ru) * 2017-12-04 2018-11-02 Ирина Геннадьевна Мариничева Имплантат для контурной пластики голени
WO2020021482A3 (fr) * 2018-07-25 2020-04-16 Establishment Labs S.A. Implants à forme symétrique
WO2020131172A1 (fr) * 2018-12-21 2020-06-25 Tepha, Inc. Poches résorbables non tissées pour implants de dispositifs médicaux
USD905855S1 (en) 2019-08-01 2020-12-22 Mentor Worldwide Llc Implant shell having internal, circumferential ribs
US10898313B2 (en) 2018-08-10 2021-01-26 Mentor Worldwide Llc Systems, devices and methods of making mammary implants and tissue expanders having ribbed shells
USD931460S1 (en) 2019-08-01 2021-09-21 Mentor Worldwide Llc Implant shell having internal, global ribs
KR20220118193A (ko) * 2021-02-18 2022-08-25 오스템임플란트 주식회사 측면 안정성이 우수한 인공 보형물 및 그 제조방법
WO2022182039A1 (fr) * 2021-02-25 2022-09-01 오스템임플란트 주식회사 Procédé de fabrication d'une prothèse mammaire artificielle
US11471268B2 (en) 2020-04-25 2022-10-18 Mentor Worldwide Llc Implants having gel zones with higher levels of cohesiveness for eschewing scalloping, dimpling, and wrinkling

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US9463087B2 (en) 2014-03-31 2016-10-11 Mentor Worldwide Llc Directional tissue expander
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US9707073B2 (en) * 2015-09-05 2017-07-18 Apex Medical Device Design Llc Pyramid-shaped breast implant for breast augmentation and/or breast lift with a method of use and production of the same
BR112018016211A8 (pt) 2016-02-09 2023-02-23 Estab Labs Sa Transponders, conjunto de portas integrado, métodos e sistema para transmitir um sinal específico de transponder
IL265954B2 (en) 2016-10-28 2024-03-01 Estab Labs S A Tissue expanders, production methods and patterns thereof
WO2022177232A1 (fr) * 2021-02-18 2022-08-25 오스템임플란트 주식회사 Implant artificiel et son procédé de fabrication
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Cited By (35)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100114311A1 (en) * 2008-11-05 2010-05-06 Hilton Becker Multi-Lumen Breast Prothesis and Improved Valve Assembly Therefor
US20120197393A1 (en) * 2009-10-16 2012-08-02 Yu Won-Seok Silicone artificial breast prosthesis which minimizes stress concentration, and production method therefor
US8480736B2 (en) * 2009-10-16 2013-07-09 Won-Seok YU Silicone artificial breast prosthesis which minimizes stress concentration, and production method therefor
US9408692B2 (en) 2010-09-28 2016-08-09 Won Seok Yu Round or anatomical type silicone prosthesis having shell with enhanced durability and method for manufacturing same
EP2724688A2 (fr) * 2011-06-23 2014-04-30 Won-Seok Yu Implant mammaire en silicone qui minimise la concentration de contraintes et son procédé de fabrication
CN103917193A (zh) * 2011-06-23 2014-07-09 刘源硕 最小化应力集中的硅胶乳房假体及其制造方法
EP2724688A4 (fr) * 2011-06-23 2015-03-18 Won-Seok Yu Implant mammaire en silicone qui minimise la concentration de contraintes et son procédé de fabrication
US20200323624A1 (en) * 2012-09-17 2020-10-15 Jamm Technologies, Inc. Breast implants with integrated transponders
US10631976B2 (en) 2012-09-17 2020-04-28 Jamm Technologies, Inc. Method of manufacturing breast implants with integrated transponders
US9901438B2 (en) 2012-09-17 2018-02-27 Jamm Technologies, Inc. Method of manufacturing breast implants with integrated transponders
US11701219B2 (en) * 2012-09-17 2023-07-18 Jamm Technologies, Inc. Breast implants with integrated transponders
US10882195B2 (en) * 2013-10-22 2021-01-05 Cornell University Method for making a soft actuator device
US20160250758A1 (en) * 2013-10-22 2016-09-01 Cornell University Soft robot device and related fabrication methods
US9980781B2 (en) * 2015-07-21 2018-05-29 Jason Leedy Breast implant sizer assembly and method
US20170020620A1 (en) * 2015-07-21 2017-01-26 Jason Leedy Breast implant sizer assembly and method
WO2018155874A1 (fr) * 2017-02-21 2018-08-30 가톨릭관동대학교산학협력단 Implant médical
US20180243569A1 (en) * 2017-02-28 2018-08-30 Boston Scientific Neuromodulation Corporation Implantable Medical Device with a Silicone Housing
US10758734B2 (en) * 2017-02-28 2020-09-01 Boston Scientific Neuromodulation Corporation Implantable medical device with a silicone housing
RU2671587C1 (ru) * 2017-12-04 2018-11-02 Ирина Геннадьевна Мариничева Имплантат для контурной пластики голени
WO2020021482A3 (fr) * 2018-07-25 2020-04-16 Establishment Labs S.A. Implants à forme symétrique
EP4082478A1 (fr) * 2018-07-25 2022-11-02 Establishment Labs S.A. Implants à forme symétrique
US11672648B2 (en) * 2018-07-25 2023-06-13 Establishment Labs S.A. Implants with symmetric shape
US20220257366A1 (en) * 2018-07-25 2022-08-18 Establishment Labs S.A. Implants with symmetric shape
US10898313B2 (en) 2018-08-10 2021-01-26 Mentor Worldwide Llc Systems, devices and methods of making mammary implants and tissue expanders having ribbed shells
WO2020131172A1 (fr) * 2018-12-21 2020-06-25 Tepha, Inc. Poches résorbables non tissées pour implants de dispositifs médicaux
US11612754B2 (en) 2018-12-21 2023-03-28 Tepha, Inc. Resorbable nonwoven pouches for medical device implants
USD931460S1 (en) 2019-08-01 2021-09-21 Mentor Worldwide Llc Implant shell having internal, global ribs
USD905855S1 (en) 2019-08-01 2020-12-22 Mentor Worldwide Llc Implant shell having internal, circumferential ribs
US11471268B2 (en) 2020-04-25 2022-10-18 Mentor Worldwide Llc Implants having gel zones with higher levels of cohesiveness for eschewing scalloping, dimpling, and wrinkling
US11844687B2 (en) 2020-04-25 2023-12-19 Mentor Worldwide Llc Methods of making implants having gel zones with higher levels of cohesiveness for eschewing scalloping, dimpling, and wrinkling
KR20220118193A (ko) * 2021-02-18 2022-08-25 오스템임플란트 주식회사 측면 안정성이 우수한 인공 보형물 및 그 제조방법
KR102648310B1 (ko) 2021-02-18 2024-03-18 오스템임플란트 주식회사 측면 안정성이 우수한 인공 보형물 및 그 제조방법
WO2022182039A1 (fr) * 2021-02-25 2022-09-01 오스템임플란트 주식회사 Procédé de fabrication d'une prothèse mammaire artificielle
KR20220121966A (ko) * 2021-02-25 2022-09-02 오스템임플란트 주식회사 인공유방 보형물 제조방법
KR102580384B1 (ko) * 2021-02-25 2023-09-21 오스템임플란트 주식회사 인공유방 보형물 제조방법

Also Published As

Publication number Publication date
ES2537659T3 (es) 2015-06-10
US9486308B2 (en) 2016-11-08
EP2467175B1 (fr) 2015-02-25
WO2011022235A3 (fr) 2011-06-16
CA2771613A1 (fr) 2011-02-24
US20190175332A1 (en) 2019-06-13
AU2010284503A1 (en) 2012-03-15
US10251746B2 (en) 2019-04-09
AR081086A1 (es) 2012-06-13
EP2467175A2 (fr) 2012-06-27
US20170071726A1 (en) 2017-03-16
WO2011022235A2 (fr) 2011-02-24
US20140077411A1 (en) 2014-03-20

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