SOFT FILLED PROSTHESIS SHELL WITH VARIABLE TEXTURE

Abstract

A soft prosthetic implant, such as a silicone breast implant, is provided. The implant has a variety of different surfaces, for example, different textures, located on different areas of the outer surface of the implant.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 15/282,587, filed on Sep. 30, 2016, which is a continuation of U.S. patent application Ser. No. 14/714,058, filed on May 15, 2015, which claims priority to, and the benefit of, U.S. Provisional Patent Application No. 61/994,772, filed on May 16, 2014, the entire disclosure of each of which is incorporated herein by this specific reference.

FIELD OF THE INVENTION

The present invention relates to soft prosthetic implants and, more particularly, to textured exterior surfaces of such implants, for instance, breast implants.

BACKGROUND OF THE INVENTION

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, which 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 flexible envelope or shell made of vulcanized (cured) silicone elastomer. The shell is filled either with a silicone gel or with a normal saline solution. The filling of the shell takes place before or after the shell is inserted through an incision in the patient.

In the United States, women can choose between two different types of breast implant shell surfaces: a smooth surface and a textured surface. The surgeon generally recommends the type of surface based on his or her technique and the shape of the breast implant chosen to best fit the needs of each patient.

Breast implants are not without complications, one of which is termed capsular contracture. This is a complication that occurs upon contraction of a fibrous outer capsule that forms around the implant, which tends to render the implant spherical and stiff and aesthetically undesirable. According to the United States Food and Drug Administration's (FDA) Breast Implant Consumer Handbook (2004), the literature shows that textured surface breast implants may decrease the capsular contracture rate.

Texturing may be provided in a number of ways. Silicone gel breast implants covered with a thin layer of textured polyurethane foam enjoyed considerable popularity in the 1980s because of their remarkable resistance to the early development of fibrous capsular contracture. For example, U.S. Pat. No. 3,293,663 describes a soft gel-filled prosthesis with a porous polyester fabric on the back side for tissue ingrowth and anchoring to the chest wall. Although these devices are no longer available in the U.S. because of regulatory constraint, their medical and commercial success stimulated interest in surface texturization of silicone implants.

Despite many advances in the development of safe and comfortable prosthetic implants, there remains room for improvement.

SUMMARY OF THE INVENTION

The present invention provides a prosthesis suitable for implantation in a human being, for example, a breast implant suitable for use in reconstruction or augmentation of the human breast. The prosthesis generally comprises an implantable member, for example, an elastomeric shell that is filled or is fillable with a liquid or gel. The implantable member has an exterior surface including one or more fixation regions defined thereon and configured, positioned or structured to provide enhanced or controlled tissue ingrowth or adhesion.

In accordance with one aspect of the invention, the fixation surfaces are discrete surface portions extending across an anterior face or a posterior face of the implant. These fixation surfaces, sometimes herein referred to as “fixation regions,” are generally defined by a texture, roughness or sheen that is different from a texture, roughness or sheen of adjacent surface portions of the implant.

In some embodiments, the fixation regions have an increased or enhanced texture relative to the balance of the anterior face or posterior face of the implant. In other words, the balance of the exterior surface may be relatively less textured than the fixation regions. In some embodiments, the fixation regions are textured and adjacent surfaces, for example, the surface or surfaces that are not defined by the fixation regions, are substantially less textured, or are relatively smooth.

The prosthesis may be structured to encourage enhanced tissue ingrowth or adhesion at the fixation regions, relative to an otherwise identical surface without such texture, roughness or sheen.

In one aspect of the invention, the fixation regions are positioned and/or configured such that the prosthesis, after implantation in the body, moves more naturally with the human body, for example, in relative unity with the muscles of the body. It is contemplated that because the implant moves more naturally with the human body, the implant may be less prone to wear resulting from material stresses relative to conventional implants, for example, implants without such fixation regions. Furthermore, it is contemplated that the present implants will be more comfortable to the patient in that they will move more naturally with the body.

In a more specific aspect of the invention, the fixation regions may be located at specific regions on an anterior face of the shell, that is, a face of the shell which faces the front of the human body when the implant has been appropriately implanted in the human body. Alternatively or additionally, one or more discrete fixation surfaces may be provided on a periphery of the shell (e.g. circumferentially) and/or on the posterior face of the shell, that is, the face of the shell that faces the back of the human body when the implant has been implanted in the human body.

In an even more specific aspect of the invention, the fixation regions comprise at least one elongated region located on the anterior face of the shell. The at least one elongated region may be, for example, a band-shaped region or alternatively, a plurality of band shaped regions having enhanced texture, roughness or sheen.

In another broad aspect of the invention, the prosthesis comprises a breast implant having a shell including a fixation region having a first texture and a balance of the shell surface having a second texture that is different from the first texture. In other words, in some embodiments of the invention, the entire, or substantially entire, exterior of the breast implant shell is a textured surface with specific regions thereof having a greater degree of texturing relative to the remaining portions of the textured surface.

It is contemplated that such different texturing will stimulate or encourage different degrees of tissue ingrowth or adhesion at the different fixation regions. For example, in one embodiment, the first fixation region is located on a posterior face of the implant and the second fixation region is located on an anterior face of the implant. The first fixation region may be defined by a texture that is more conducive to tissue interaction and adhesion whereas the second fixation region may be defined by a texture that is relatively less conducive to tissue interaction and adhesion.

In yet another aspect of the invention, the prosthesis comprises a shell having an exterior structured to contact tissue, the shell including a first fixation surface having a first open cell structure, and a second fixation surface having a second open cell structure different than said first open cell structure. In addition, the first fixation surface and the second fixation surface are positioned to encourage respectively different degrees of tissue ingrowth or tissue adhesion by the body at a body-shell interface.

For example, the first open cell structure comprises relatively large open cells and the second open cell structure comprises relatively smaller open cells. Alternatively or additionally, the first open cell structure may comprise a first distribution of cells and the second open cell structure comprises a second distribution of cells wherein the first distribution of cells is relatively more dense than the second distribution of cells.

In yet another specific aspect of the invention, the first open cell structure comprises relatively large rounded open cells and the second open cell structure comprises relatively small rounded open cells. Alternatively, the first open cell structure comprises relatively rounded open cells and the second open cell structure comprises relatively angular open cells.

Advantageously, in accordance with certain embodiments, the first and second fixation surfaces are positioned and structured to be at least somewhat effective to disrupt or disorient capsular tissue formation about the prosthesis after the prosthesis has been implanted in the body.

The present invention further provides a breast prosthesis shell for implantation in a human being, the shell manufactured by the steps of providing a shell precursor; applying a layer of silicone elastomer to the shell precursor, applying solid particles of a first configuration to a portion of the layer of silicone elastomer and applying solid particles of a second configuration to another portion of the layer of silicone elastomer before the layer is fully cured. After the layer including the solid particles embedded therein is cured, the solid particles are then dissolved, for example, by means of a solvent that does not dissolve the silicone elastomer to any appreciable extent. The resulting elastomer shell includes a first open cell texture region formed by said application of the solid particles of the first configuration, and a second open cell texture region formed by said application of the solid particles of the second configuration.

In yet another aspect of the invention, a method of augmenting or reconstructing a breast of a human being is provided. The method generally comprises providing an implantable member including at least one elongated fixation region as described elsewhere herein and implanting the implantable member into a breast of a human being such that the fixation region generally aligns with one of the pectoralis major muscle group and the pectoralis minor muscle group. The method may further comprise filling the implantable member with a liquid or gel prior to or after the implanting step.

A further understanding of the nature and advantages of the present invention are set forth in the following description and claims, particularly when considered in conjunction with the accompanying drawings in which like parts bear like reference numerals.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and advantages of the present invention will become appreciated as the same become better understood with reference to the specification, claims, and appended drawings wherein:

FIGS. 1A-1B are a front view and a side elevational view, respectively, of an exemplary round breast implant of the present invention;

FIGS. 2A-2B are a front view and side elevational view, respectively, of an exemplary shaped breast implant of the present invention;

FIGS. 3A and 3B are schematic views of a woman's upper torso showing, alignment of the pectoralis major muscle group and the pectoralis minor muscle group, respectively;

FIGS. 4A and 4B are vertical sectional views through a woman's breast and adjacent chest anatomy showing, respectively, subglandular and submuscular placement of a breast implant;

FIGS. 5A-5B are front and side elevational views of an exemplary round breast implant of the present invention having a generally elongated or band-shaped fixation surface;

FIGS. 6A-6B are front and side elevational views of an exemplary shaped breast implant of the present invention having a generally elongated or band-shaped fixation surface;

FIG. 7 is a front elevational view of another breast implant in accordance with the invention including a first fixation region having a first texture and a second fixation region having a second texture different from the first texture;

FIGS. 8A and 8B are front and rear elevational views of an exemplary round breast implant of the present invention having a front texture and a rear texture that are different from one another;

FIG. 9 is a side view of a breast implant in accordance with another embodiment of the invention;

FIG. 10 is a side view of a breast implant in accordance with yet another embodiment of the invention; and

FIG. 11 is a side view of a breast implant in accordance with yet a further embodiment of the invention.

DETAILED DESCRIPTION

The present invention provides a saline- or gel-filled soft implant shell, preferably a silicone elastomer shell, with a fixation surface over an exterior portion. The primary application for such soft implants is to reconstruct or augment the female breast. Other potential applications are implants for the buttocks, testes, or calf, among other areas.

The terms “fixation surface” or “fixation region”, as used herein, generally refer to a region or portion of an exterior surface of an implant which is positioned, structured or adapted to encourage tissue ingrowth or adhesion at a body/implant interface. For example, a fixation region may be a texture, roughness or sheen that is distinct from, for example, more pronounced than, adjacent surfaces of the implant which do not encourage tissue ingrowth of adhesion to the same degree as the fixation region. For example, other regions or surfaces of the implant exterior may be relatively smooth or less textured relative to the fixation regions.

Such a fixation region may be formed by any suitable means, for example, but not limited to, a salt removal process such as described in U.S. Pat. No. 5,007,929, with appropriate changes being made. Alternatively, the fixation surfaces may be formed by separate textured elements such as textured patches or films adhered to the outside of an otherwise “smooth” or less textured implant. Still, another method for forming the discrete fixation regions may be by using a relatively roughened surface portion of a mold used to form the implant. Another method for forming the present fixation regions includes texturing the exterior of the implant after formation. The present invention should not be considered limited to any particular type of texturing or fixation surface, though there might be certain advantages with one or more of these techniques.

Turning now to the Figures, FIGS. 1A and 1B are front and side elevational views of an exemplary round breast implant 20. Generally, the implant 20 comprises an exterior surface defined by a relatively smooth anterior face 21, a textured posterior face 22 and a textured peripheral region 24 located between the anterior face 21 and the posterior face 22. The relatively smooth anterior face may be a relatively less textured surface (relative to texture of posterior face 22), such as, for example, a fine textured surface or even a matte finish. In some embodiments, the implant 20 has a relatively smooth posterior face, a textured anterior face and a textured or smooth peripheral region. The fixation surfaces 22, 24 themselves may have differing degrees of texturing. The diameter D and front-to-back thickness T of the implant are shown and vary depending on the patient's chest size and aesthetic considerations.

In the shown embodiment, the rear fixation surface 22 extends to the apex 26 or generatrix of the convex outer periphery of the implant 20. The peripheral fixation surface 24 continues forward a short distance S onto the anterior or front surface 21. In some embodiments, the distance S is between about 10% and about 30% of the thickness T. In some embodiments, the peripheral fixation surface 24 extends substantially entirely around the periphery of the implant 20, such that the implant 20 is axi-symmetric. In other embodiments, the peripheral fixation surface 24 may be abbreviated so as to extend around only a portion of the periphery of the implant, such as the inferior or superior half, or the peripheral fixation surface may be broken up into spaced apart segments. In some embodiments, the peripheral fixation surface 24 comprises substantially evenly spaced segments resulting in alternating smooth and textured areas.

FIGS. 2A-2B illustrate an exemplary shaped breast implant 30 of the present invention having an inferior frontal lobe 32 simulating a natural breast. Like implant 20, implant 30 includes a rear fixation surface 34 and a peripheral fixation surface 36. The width W, height H, and front-to-back thickness T of the implant are shown. If the front projection is round, then W=H, otherwise W may be greater than or less than H. When provided with a natural shape, the implant 30 has a proper orientation, namely with the inferior lobe 32 at the lower center. Accordingly, the peripheral fixation surface 36 may extend completely around the periphery of the implant, or may be formed in discrete areas and be oriented relative to the natural shape of the implant. For example, the peripheral fixation surface 36 may be formed only around the inferior or lower half of the implant, or may be formed only on the sides.

FIG. 3A illustrates a woman's upper torso schematically showing on one side placement and alignment of the pectoralis major muscle group, while FIG. 3B illustrates the placement and alignment of the pectoralis minor muscle group. These two muscle groups overlap one another and extend generally from the shoulder or collarbone region to the rib cage underneath the breast. One aspect of the present invention is to provide an implant including fixation surfaces such as described elsewhere herein, which are substantially aligned with these muscle groups when the implant is placed in the body.

While not wishing to be bound by any specific theory of operation, the regions or lines of contact of the implant with the primary chest muscles experience greater movement than other areas of the implant not interfacing the muscles. It is believed by the present inventors that by providing a fixation region of the implant that is substantially coincident with or in substantial alignment with one or more of these muscle groups is more likely to remain secured (i.e., they move with the muscle). In addition, it is contemplated that such discrete fixation regions may provide the benefit of disrupting capsule formation and/or reducing the potential for capsular contraction.

FIG. 4A is a vertical sectional view through a woman's breast and adjacent chest anatomy showing a subglandular placement of a breast implant 40. The implant 40 is positioned over the top of the pectoralis major muscle group 42, which in turn overlays the pectoralis minor muscle group 44. The chest wall 48 showing a plurality of ribs 50 is also indicated underneath the pectoralis minor muscle 44. FIG. 4B is a vertical sectional view as in FIG. 4A but showing a submuscular placement of the implant 40, underneath the pectoralis major muscle group 42. Both these two implant placements are utilized primarily depending on the surgeon's clinical determination, sometimes influenced by a dialogue between patient and the surgeon and desired outcome. Depending on the implant placements, the implant 40 may be in contact with one or both muscle groups. In some embodiments of the invention, the implant includes substantially elongated fixation regions as described and shown herein, and said fixation regions being in substantial alignment with the appropriate muscle group which interface the implant when the implant is placed in the body.

For example, FIGS. 5A-5B are front and side elevational views of an exemplary round breast implant 60 of the present invention having a posterior face 62, a peripheral region 64, and an anterior face including an elongated or band-shaped fixation region 66. The band-shaped fixation region 66 extends generally along a diagonal angle and commences at the front border of the peripheral fixation surface 64. The illustrated embodiment, the fixation region 66 has a substantially constant width W as seen from the front in FIG. 5A. In one embodiment, the width W is between about 1 mm to about 20 mm, for example, between about 2 mm to about 15 mm. Alternatively, although not shown, the fixation region 66 may have a configuration that is other than a constant width.

In one embodiment, the band-shaped fixation surface 66 is generally oriented or aligned with either the pectoralis major muscle group or pectoralis minor muscle group when the implant is implanted in the breast. For instance, if the implant 60 is destined for a submuscular placement such as in FIG. 4B, the fixation surface 66 may be oriented to be generally aligned with the pectoralis major muscle group, as seen in FIG. 3A. Alternatively, the angle at which the insertion surface 66 is oriented may be an approximation of the average angle of the pectoralis major and pectoralis minor muscle groups. In this way, the implant 60 has a fixation surface 66 to encourage tissue ingrowth or adhesion along the major stress lines of the implant. Preferably, the fixation surface 66 is angled between about 30-60° with respect to a vertical plane through the implant 60. Of course, if the implant 60 is round as shown, the fixation surface 66 itself defines the orientation thereof. In one embodiment, the band-shaped fixation surface 66 is centered about the center of the implant 60, therefore creating two symmetric orientations about 180° apart. This arrangement facilitates implant by providing two possible orientations for the surgeon.

The band-shaped fixation region 66 may extend substantially across the anterior face of the implant and may be defined by a texture that is different from a balance of the anterior face. The fixation region 66 may also have a different texture, for example, a more pronounced or more aggressive texture, than the rear fixation surface 62 or peripheral surface 64.

FIGS. 6A-6B illustrate another exemplary shaped breast implant 70 of the present invention. The implant 70 again features a rear fixation surface 72, a peripheral fixation surface 74, and a plurality of separate band-shaped fixation surfaces 76a, 76b, 76c. These discrete fixation surfaces 76a, 76b, 76c are positioned or configured to align with one or more of the muscle groups described above. For example, the three fixation surfaces 76a, 76b, 76c may be generally oriented relative to the fan-shaped pectoralis minor muscle group. Because the shaped implant 70 is orientation-specific, proper placement of the implant orients the fixation surfaces 76a, 76b, 76c with the particular muscle group. As mentioned above, the various fixation surfaces 72, 74, 76a, 76b, and 76c may be formed with a similar level of roughness, or some may be less textured, such as with a matte finish. For instance, the rear and peripheral fixation surfaces 72, 74 may have a fine, matte finish, while the frontal fixation surfaces 76a, 76b, 76c are more densely textured. The present invention contemplates all permutations of texturing choices.

In cross-section, the textured implant shells of the present invention may be single- or multi-layered. The overall thickness of the textured implant shell wall may be somewhat greater than a similar smooth-walled shell because of the extra layers of texture.

Turning now to FIG. 7, an anterior (front) view of another breast implant of the present invention is shown generally at 110. The implant 110 includes a shell 112 having an exterior surface including a first fixation region 114 having a first texture 116 and a second fixation region 118 having a second texture 122 that is different from the first texture 116. In the shown embodiment, the first texture 116 is a more “aggressive” texture than the second texture 122. The first texture 116 is structured to encourage a greater degree of tissue interaction than the second texture 122.

In lieu of the second texture 122, it is contemplated that the second fixation region 118, and perhaps the entire balance of the exterior of the shell 112, may be a low sheen surface, for example, a matte finish.

Turning now to FIGS. 8A and 8B, anterior (front) and posterior (rear) views, respectively, of another breast implant in accordance with the invention are shown generally at 210. The implant 210 includes a shell 212 having an anterior face 212a and a posterior face 212b, and including a first fixation region 214 having a first texture 216 and a second fixation region 218 having a second texture 222 that is different from the first texture 216. In the shown embodiment, the first texture 216 may encompass the entire, or substantially entire, anterior face 212a of the implant 210. The first texture 216 is defined by a first distribution of pores, crevices or caverns that is relatively less dense than that of the second texture 222. The second texture 222, which may encompass the entire, or substantially entire, posterior face 221b of the implant 210, may be structured to encourage a greater degree of tissue interaction and adhesion than that of the first texture 216.

In another aspect of the invention, a breast implant is provided, the implant comprising an elastomeric shell comprising a first region and a second region, and an outer surface, the first region defined by a first textured surface of the shell; and the second region defined by a second surface of the shell that is different from the first textured surface of the shell. In some embodiments, the first textured surface is substantially defined by interconnected pores extending a depth of between about 0.2 mm to about 5.0 mm into the shell outer surface.

In some embodiments, the interconnected pores of the first textured surface extend at least about two to about five pore diameters deep into the shell outer surface. Such a surface can be made using alternating porogens and elastomer on the surface of the breast implant shell, to gain the desired depth of porosity, fusing the porogens, and removing the porogens to leave the interconnected porous structure that overlies a non-porous layer of the shell which contains the silicone gel filling.

For example, the pores may be made with dissolvable porogen beads, having a diameter of between about 100 micron to about 1000 micron, between about 200 micron to about 800 micron, or a diameter of between about 300 micron to about 700 micron, or a diameter of between about 400 micron to about 600 micron.

In some embodiments, the size of the pores of the porous textured surface will be somewhat equivalent to the size of the porogens used to form the pores. In some embodiments, at least about 50%, or about 80%, or about 70% ort about 80%, or about 90% of the pores have a diameter of a uniform size, for example, a diameter of about 100 micron, about 200 micron, about 300, micron, about 400 micron, about 500 micron, about 600 micron, about 700 micron, about 800 micron, about 900 micron or about 1000 micron or greater.

In some embodiments, the pores have a diameter of between about 100 micron to about 1000 micron, for example, wherein at least about 50%, or about 60%, or about 70%, or about 80%, or about 90% of the pores have a diameter in a range of between about 100 micron to about 1000 micron, between about 200 micron to about 800 micron, between about 300 micron to about 700 micron, or between about 400 micron to about 600 micron.

For example, in one embodiment, the first textured surface is defined by pores extending about 2 to about 5 pores deep and about 90% of the pores have a diameter of between about 400 micron to about 600 micron. The second surface in this and other embodiments may comprise a second textured surface defined by pores extending no greater than about one pore deep into the shell outer surface.

In some embodiments, the second surface is a substantially smooth surface, or a less porous surface, or a less textured surface, or is a surface that allows for less tissue ingrowth, relative to the first textured surface.

In one embodiment, a breast implant having a variable textured surface is provided, the implant comprising an elastomeric shell comprising a first region and a second region, an outer surface, and an anterior side and a posterior side, the first region defined by a first textured surface of the shell, the first textured surface being substantially defined by interconnected pores extending at least about two to about five pore diameters deep to a depth of between about 0.8 mm to about 3.0 mm into the shell outer surface, wherein the pores have a diameter of between about 400 micron to about 600 micron; and the second region defined by a second surface of the shell that is different from the first textured surface of the shell, the second surface defined by a surface selected from a group of surfaces consisting of a smooth surface, a second textured surface that is less porous than the first textured surface, a third textured surface having concavities extending no greater than about one pore deep into the shell outer surface, and a fourth textured surface having concavities extending less than one pore deep into the shell outer surface.

Further still, such as shown in FIGS. 9-11 to be discussed hereinafter, the first region, comprising a region more textured or more conducive to tissue ingrowth, may be disposed on at least a portion of an anterior side of the shell, and the second region comprising a relatively smooth, or less textured, or less conducive to tissue ingrowth, may be being disposed on at least a portion of a posterior side of the shell. Such an implant in accordance with this embodiment is structured to facilitate surgical removal of the implant from a patient. For example, the implant provides for easier surgical removal relative to an implant that is fully textured on all of the outer surfaces of the implant.

For example, the first surface of the implant, disposed at least in part on the anterior side of the implant, and having a deeply porous texture than the second surface, provides a structure for greater tissue integration and may also reduce capsular formation and/or capsular contraction. The posterior side of the implant may be smooth or may include a lighter, less porous texture which provides for minimal tissue integration. In some instances, the pore size of the first textured surface and the pore size of the second textured surface may be substantially the same, with the depth of porosity being the distinction between the two surfaces. In another embodiment, the pore size may be different between the two surfaces, but with the first textured surface providing for greater tissue integration than the second surface.

In these embodiments, the present implant is structured to provide certain aesthetic and surgical advantages over prior art implants. Surgically, for example, the anterior portion of the implant can be readily accessed through the original incision, for example inframammary incision, and the integrated tissue can be visualized and surgically separated from the more textured surfaces of the implant. The posterior side of the implant, which is by nature more difficult to access surgically access, can be separated from the tissue by simple finger dissection of peeling away of the implant due to its minimal tissue integration. Aesthetically, tissue adherence advantageously can maintain a desired position of the implant in the breast, preventing rotation or migration, and maintaining correct orientation of anatomically shaped implants.

FIGS. 9, 10 and 11 show additional embodiments of the invention in which first and second surface textures are located on different regions of an implant in accordance with the invention, and which can provide at least one or more of the advantages described above with respect to maintaining correct positioning and facilitating surgical removal if needed.

FIG. 9 is a side view of a breast implant 310 in accordance with one embodiment of the invention. In this embodiment, implant 310 includes a first surface region 316 and a second surface region 322. Second surface region 322 is different, in terms of texture or smoothness, relative to first surface region 316. For example, second surface region 322 is relatively less textured, less porous, and/or less conducive to tissue ingrowth, relative to first surface region 316. In some embodiments, the porosity of first surface region 316 is a multiple-pore depth texture, the porosity of this texture extending from an outer surface 324 of the implant 310 to a depth that is several pores in depth, for example, about 3, 4 or 5 or more pores in depth. In contrast, second surface region may be relatively smooth, untextured, having open cavities, single-pore depth, or half-pore depth, generally lacking deep cavities beneath the surface, or otherwise lacking significant texture conducive to tissue ingrowth relative to first surface region 316. As shown, first surface region 316 may extend on a portion, for example, on a portion of the anterior face of the implant 310, without extending into the outer perimeter region.

FIG. 10 is a side view of a breast implant 410 in accordance with yet another embodiment of the invention. In this embodiment, implant 410 includes a first surface region 416 and a second surface region 422. Second surface region 422 is different, in terms of texture or smoothness, relative to first surface region 416. For example, second surface region 422 is relatively less textured, less porous, and/or less conducive to tissue ingrowth, relative to first surface region 416. In some embodiments, the porosity of first surface region 416 is a multiple-pore depth texture, the porosity of this texture extending to a depth that is several pores in depth, for example, about 3, 4 or 5 or more pores in depth. In contrast, second surface region may be relatively smooth, untextured, having open cavities, single-pore depth, or half-pore depth, generally lacking deep cavities beneath the surface, or otherwise lacking significant texture conducive to tissue ingrowth relative to first surface region 416. As shown, first surface region 416 may extend on a portion, for example, on a lower portion of the anterior face of the implant 410, and second surface region 422 may extend on a portion, for example, an upper portion, of the posterior face of the implant 410.

FIG. 11 is a side view of a breast implant 510 in accordance with yet another embodiment of the invention. In this embodiment, implant 510 includes a first surface region 516 and a second surface region 522. Second surface region 522 is different, in terms of texture or smoothness, relative to first surface region 516. For example, second surface region 522 is relatively less textured, less porous, and/or less conducive to tissue ingrowth, relative to first surface region 416. In some embodiments, the porosity of first surface region 516 is a multiple-pore depth texture, the porosity of this texture extending to a depth that is several pores in depth, for example, about 3, 4 or 5 or more pores in depth. In contrast, second surface region may be relatively smooth, untextured, having open cavities, single-pore depth, or half-pore depth, generally lacking deep cavities beneath the surface, or otherwise lacking significant texture conducive to tissue ingrowth relative to first surface region 516. As shown, first surface region 516 may extend on a portion, for example, on a lower and anterior portion of the implant 510, and second surface region 522 may extend on the posterior face of the implant 510 as well as portions of the anterior face of the implant.

Numerous other arrangements are possible and are considered to be within the scope of the present invention.

One process for forming flexible implant shells for implantable prostheses involves dipping a suitably shaped mandrel into a silicone elastomer dispersion. Many such dispersions are used in the field. Basically they contain a silicone elastomer and a solvent. The silicone elastomer is typically polydimethylsiloxane, polydiphenyl-siloxane or some combination of these two. Typical solvents include xylene or 1,1,1-trichloroethane. Different manufacturers vary the type and amount of the ingredients in the dispersion, the viscosity of the dispersion and the solid content of the dispersion. Nonetheless, the present invention is expected to be adaptable to have utility with a wide variety of silicone rubber dispersions.

The mandrel is withdrawn from the dispersion and the excess silicone elastomer dispersion is allowed to drain from the mandrel. After the excess dispersion has drained from the mandrel at least a portion of the solvent is allowed to volatilize or evaporate. Normally this is accomplished by flowing air over the coated mandrel at a controlled temperature and humidity. Different manufacturers use various quantities, velocities or directions of air flow and set the temperature and humidity of the air at different values. However, the desired result, driving off the solvent, remains the same.

An exemplary process for forming the textured surfaces, or fixation surfaces on a molded silicone shell will now be described. After the mandrel is raised out of the silicone dispersion with what is to be the final layer adhering thereto, this layer is allowed to stabilize. That is, it is held until the final coating no longer flows freely. This occurs as some of the solvent evaporates from the final coating, raising its viscosity.

Once the flexible shell has been stabilized, any loose fibers or particles are removed from the exterior of the shell, for example, with an anti-static air gun. A tack coat layer is then applied. The tack coat layer may be sprayed on, but is desirably applied by dipping the flexible shell on the mandrel into a tack coat dispersion. The operator immerses the flexible shell into the dispersion and returns the mandrel to a rack for stabilization. The time required for stabilization typically varies between 5-20 minutes. A suitable tack coat layer is desirably made using the same silicone dispersion material employed in the base layers.

At this point, dissolvable particles, texturing beads, or porogens (for example, dissolvable sugar or polymer particles) are applied over that portion of the exterior surface to be textured. The solid particles may be applied manually by sprinkling them over the tacky surface while the mandrel is manipulated, or a machine operating like a bead blaster or sand blaster could be used to deliver a steady stream of solid particles at an adequate velocity to the coating on the mandrel. The portion of the shell that is not to be textured may be masked during the application of the particles. One method of particle application is to dip the mandrel/shell into a body of the solid particles or expose it to a suspension of the solid particles.

The tacky flexible shell may then be immersed in a fluidized (air-mixing) aqueous bath of the porogens. After a suitable period of stabilization, such as between about 5-20 minutes, the shells may be dipped into an overcoat dispersion. A suitable overcoat dispersion may be made using the same material employed in the base layers. Alternating layers of porogens and silicone dispersion may be used to create a depth of texturing desired. The coated shells on the mandrels may then be then mounted on a rack and allowed to volatilize, such as, for example, about 15 minutes.

The entire silicone elastomer shell structure may be vulcanized or cured in an oven at elevated temperatures. The temperature of the oven may be kept between about 200° F. and about 350° F. for a curing time preferably between about 20 minutes and about 1 hour, 40 minutes. Upon removal from the oven, the mandrel/shell assembly is placed in a solvent for the porogens, and the porogens allowed to dissolve. The solvent does not affect the structure or integrity of the silicone elastomer. When the porogens have dissolved, the assembly is removed from the solvent and the solvent evaporated. The shell can then be stripped from the mandrel. At this point, it is preferable to place the shell in a solvent for the porogens and gently agitate it to ensure complete dissolution of all the porogens. When the shell is removed from the solvent, the solvent is evaporated.

Dissolving the porogens leaves behind open, interconnected, cavities in the surface of the shell where the porogens had been.

After finishing the shell according to the steps described above, the steps required to make a finished breast implant prosthesis may be similar to those known in the art. For example, an opening left by the dip molding process is patched with uncured sheeting, usually made of silicone rubber. Then, if the prosthesis is to be filled with silicone gel, this gel is added and cured, the filled prosthesis packaged, and the packaged prosthesis sterilized. If the prosthesis is to be inflated with a saline solution, a one-way valve is assembled and installed, the prosthesis is post cured if required, and the prosthesis is then cleaned, packaged and sterilized. A combination breast implant prosthesis can also be made wherein a gel-filled sac is positioned inside the shell to be surrounded by saline solution.

In one aspect of the invention, a breast implant is provided having more significant texturing on the front, or anterior side, of the implant, and is reduced or omitted on the back, or posterior side of the implant to enhance tissue adherence on front of the implant and to reduce tissue adherence to muscle tissue on the back of the implant. For example, in some embodiments, the anterior surface of the implant includes two, three, four, five or more layers of texturing, made for example, by alternating layers of texturing particles with silicone dispersion layers, during the manufacturing process; and the posterior surface includes one layer of texturing made by application of a single layer of texturing particles (not alternated with elastomer). Alternatively, the anterior surface includes two or more layers of texturing and the posterior surface having less or no texturing. In any of the aforementioned embodiments, the depth of the porous structure of first surface region may be a relatively deep porous structure, for example, a porous structure that is multiple pores deep, for example a depth of porosity that is about 3, 4 or more pores in depth. In some embodiments, the pore size, for example, the pore diameter, is based on the size of the particles used to form the texture.

In some embodiments, about 50%, or about 70% or about 80% or about 90% of the particles used to form the texture are generally spherical beads, for example, dissolvable polymer beads, having a diameter of between about 100 micron to about 1000 micron, for example, about 200 micron to about 800 micron, for example, or about 300 micron to about 700 micron, or about 400 micron to about 600 micron in diameter.

In one embodiment, about 90% of the particles used to form the pores are between about 420 micron to about 595 micron in diameter.

In one particularly advantageous embodiment, the depth or thickness of the texture extends between about 0.2 mm to about 5.0 mm, or between about 0.4 mm to about 4.0 mm, or between about 0.8 mm to about 3.0 mm. In one embodiment, about 90% of the particles used to form the pores are between about 420 micron to about 595 micron in diameter, and the depth of the porous portion is between about 0.8 mm to about 3.0 mm.

In some embodiments, the texture of the first surface and/or second surface are made using polymer microspheres, for example, polymer microspheres having the aforementioned particle sizes or distributions. In some embodiments, the texturing is accomplished using one or more of the processes described in U.S. Pat. No. 8,685,296, issued Apr. 1, 2014, U.S. Pat. No. 8,877,822, issued Nov. 4, 2014, and/or in U.S. patent application Ser. No. 13/631,091, filed on Sep. 28, 2012, the entire disclosure of each of these documents being incorporated herein by this specific reference.

For example, a method for making the variable textured implant, for example, may comprise coating a breast implant mandrel with an elastomer base, curing the elastomer base to form a base layer, coating the cured base layer with an elastomer base, coating the elastomer base with porogens to form a porogen layer on the elastomer base. The porogens may comprise a core material and a shell material surrounding the core material. In some embodiments, the porogen comprises a shell material having a melting point temperature that is lower than a melting point temperature of the core material. The method may further comprise coating the porogen coating with another layer of elastomer, coating this layer of elastomer with another coating of porogens, (and, if desired, repeating the elastomer and porogen coating steps until a desired thickness is built up on the mandrel), treating the elastomer and porogen layers built up on the mandrel to cause the porogens to at least partially fuse to one another within the elastomer and causing the elastomer to cure, thereby forming a porogen scaffold comprising fused porogens and cured elastomer. Next, the porogen scaffold is removed from the elastomer, for example, by dissolving the porogens using a suitable dissolute. The porogen scaffold removal results in a textured implant shell having a textured surface comprising interconnected pores. This method may include masking portions of the implant shell during the layering steps to keep the other regions of the implant untextured, e.g. matte, thus producing a breast implant shell having a texture on only a first region of the implant, with a balance of the implant surface being untextured, or matte. Alternatively, the masked portion may be unmasked after the first region has been textured, and the unmasked portion may then be textured using a process different from the first region texturing process, or similar thereto but with fewer layers, for example. For example, after the first region has been textured, the unmasked portion may be layered with only one layer of porogens to produce a second region that has a lightly textured surface, or fewer alternating layers of elastomer and porogens may be used to produce a less textured, less porous, second region of the implant. Many different combinations of these steps may be used to produce the final variable textured implant as described elsewhere herein and having one or more of the surgical and/or aesthetic advantages described herein.

Although the invention has been described and illustrated with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example, and that numerous changes in the combination and arrangement of parts can be resorted to by those skilled in the art without departing from the scope of the invention, as hereinafter claimed.

Claims

1. A breast implant comprising:

an elastomeric shell comprising a first region and a second region, and an outer surface,

the first region defined by a first textured surface of the shell; and

the second region defined by a second surface of the shell that is different from the first textured surface of the shell;

the first textured surface being substantially defined by interconnected pores extending a depth of between about 0.2 mm to about 5.0 mm into the shell outer surface.

2. The implant of claim 1 wherein the interconnected pores of the first textured surface extend at least about two to about five pore diameters deep into the shell outer surface.

3. The implant of claim 1 wherein the pores have a diameter of between about 100 micron to about 1000 micron.

4. The implant of claim 1 wherein at least about 70% of the pores have a diameter of between about 100 micron to about 1000 micron.

5. The implant of claim 1 wherein at least about 90% of the pores have a diameter of between about 100 micron to about 1000 micron.

6. The implant of claim 1 wherein the pores have a diameter of between about 200 micron to about 800 micron.

7. The implant of claim 1 wherein the pores have a diameter of between about 300 micron to about 700 micron.

8. The implant of claim 1 wherein the pores have a diameter of between about 400 micron to about 600 micron.

9. The implant of claim 1 wherein at least about 90% of the pores have a diameter of between about 400 micron to about 600 micron.

10. The implant of claim 1 wherein the second surface is a second textured surface different from the first textured surface.

11. The implant of claim 4 wherein the second textured surface is defined by pores extending no greater than about one pore deep into the shell outer surface.

12. The implant of claim 1 wherein the second surface is a substantially smooth surface relative to the first textured surface.

13. The implant of claim 1 wherein the first textured surface extends a depth of between about 0.8 mm to about 3.0 mm.