COMPRESSED HIGH DENSITY FIBROUS POLYMERS SUITABLE FOR IMPLANT
An embodiment of the present invention may be made by the following steps: providing a mixture comprising a plurality of fibers, a lubricant, and a suspension fluid, with the suspension fluid filling a void space between said fibers and subjecting said mixture to at least one compressive force. The compressive force causes the migration and alignment of said fibers; and may remove substantially all of the suspension fluid from said mixture. The mixture may further comprise a biologically active agent, or a reinforcing agent.
1 ) The method of fabricating a fibrous member comprising the steps of:
a) providing a mixture, said mixture comprising a plurality of fibers, a lubricant, and a suspension fluid, said suspension fluid filling a void space between said fibers;
b) subjecting said mixture to at least one compressive force, said compressive force causing the migration and at least partial alignment of said fibers; and
c) removing substantially all of said suspension fluid from said mixture.
2 ) The method of claim 1 , wherein said mixture further comprises a biologically active agent.
3 ) The method of claim 1 , wherein said mixture further comprises a reinforcing agent.
4 ) The method of claim 2 , wherein said mixture further comprises a reinforcing agent.
5 ) The method of claim 1 , wherein said removing of said suspension fluid comprises wicking away suspension fluid that is on an exterior surface of said fibrous member.
6 ) The method of claim 2 , wherein said wicking away of suspension fluid involves compressing said mixtures against at least one wicking element
7 ) The method of claim 1 , wherein said compressive forces reduce said void space between said fibers.
8 ) The method of claim 1 , wherein said lubricant is in the form of a liquid.
9 ) The method of claim 1 , wherein said lubricant is in the form of a solid.
10 ) The method of claim 9 , wherein said solid lubricant is further provided in a carrier fluid.
11 ) The method of claim 1 , wherein said compressive force induces flow of the suspension fluid.
12 ) The method of claim 11 , wherein said suspension fluid flow causes plates of oriented fibers to be formed.
13 ) The method of claim 1 , wherein said compressive force is applied by a molding surface, thereby creating a shaped fibrous member in said mold.
14 ) The method of claim 13 , wherein said shaped fibrous member is in the shape selected from the group comprising a sheet, cylinder, block, sphere, tube, and a valve.
15 ) The method of claim 1 , further comprising the step of:
d) machining said compressed mixture.
16 ) The method of claim 1 , further comprising the step of:
d) cross-linking at least a portion of said compressed mixture by exposure to a cross-linking agent.
17 ) The method of claim 16 , further comprising the step of:
e) machining said compressed mixture.
18 ) The method of claim 1 , further comprising the step of:
d) drying said compressed mixture.
19 ) The method of claim 18 further comprising the step of:
e) cross-linking at least a portion of said dried, compressed mixture by exposure to a cross-linking agent.
20 ) The method of claim 19 further comprising the step of:
f) machining said compressed mixture.
21 ) The method of fabricating a fibrous member comprising the steps of:
a) providing a mixture, said mixture comprising a plurality of fibers, a lubricant and a suspension fluid, said suspension fluid filling a void space between said fibers;
b) subjecting said mixture to at least one compressive force, said compressive force causing the migration and at least partial alignment of said fibers;
c) cross-linking at least a portion of said mixture;
d) subjecting said at least partially cross-linked mixture to a second compressive force; and
e) removing substantially all of said suspension fluid from said mixture.