Compressed high density fibrous polymers suitable for implant

Abstract

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.