Open celled foams, implants including them and processes for making same

Abstract

Described herein are open celled foams including a matrix of interconnected spheres. Also described herein are methods of making open celled foams as well as making composite members with open celled foam coatings covering at least a portion of the composite member. The open celled foams described herein are silicone based materials and can be used to coat implants such as breast implants and function to encourage tissue ingrowth and reduce capsular formation.

What is claimed is: 
     
         1 . An open celled foam comprising:
 a matrix of interconnected spheres, said spheres comprising substantially pure silicone.   
     
     
         2 . The open celled foam of  claim 1  made by the process of:
 combining a first composition comprising a first organic solvent and at least one extractable agent, and a second composition comprising a second organic solvent and at least one silicone matrix agent thereby forming a mixture, wherein said at least one matrix agent is less than about 40% of said mixture; 
 agitating said mixture thereby forming an emulsion; and 
 curing said emulsion thereby forming said open celled foam including a matrix of interconnected spheres. 
 
     
     
         3 . The open celled foam of  claim 1  wherein said matrix of interconnected spheres has a theoretical void space of about 60% and about 88%. 
     
     
         4 . The open celled foam of  claim 1  wherein said matrix of interconnected spheres has a physical void space of about 50% to about 70%. 
     
     
         5 . The open celled foam of  claim 1  wherein said spheres have a diameter of between about 25 μm and about 200 μm.