CA2264139C - Medical electrical lead and reinforced silicone elastomer compositions used therein - Google Patents

Abstract

A medical electrical lead and a reinforced silicone elastomer used therein. The silicone elastomer used therein is preferably made from a novel silica reinforced polysiloxane material, which after vulcanization by cross-linking exhibits improved mechanical properties. The medical electrical lead feature s an electrode at a distal end thereof, a connector at a proximal end thereof and an elongated electrical conductor extending between the electrode and th e connector, the conductor in electrical contact with the electrode at a dista l end and in electrical contact with the connector at a proximal end, the conductor comprised of a plurality of wires or wire bundles wound in a multifilar coil configuration.

Description

1015202530W0 98/104313CA 02264139 l999-02- l7PCT/US97/14804lMEDICAL ELECTRICAL LEAD AND REINFORCED SILICONEELASTOMER COMPOSITIONS USED THEREINBACKGROUND OF THE INVENTION1. Field of the InventionThe present invention is directed to reinforced polysiloxane elastomercompositions of improved mechanical properties. More specifically the presentinvention is directed to reinforced polysiloxane elastomer compositions which haveimproved creep resistance, improved compression set and improved crush resistanceand are eminently suitable for use as insulators for leads of implantable medicaldevices, particularly cardiac pacemakers.2. Brief Description of the Prior ArtPolysiloxane elastomer compositions have been known in the art for a longtime. Many polysiloxane elastomer compositions of the prior art contain a silicareinforcer that has been treated to make it compatible with the generally hydrophobicpolysiloxane matrix of the elastomer. Prior art pertaining to polysiloxane materialscan be found in United States Patent Nos. 3,341,490, 3,284,406, 3,457,214,3,996,187, 3,996,189, 4,615,702, 5,236,970 and in European Patent application No.0110537 filed on October 18, 1983.Silicone elastomer rubber tubing that contains silica reinforcing material hasbeen extensively used as insulator on electrical leads, particularly on leads ofimplantable medical devices, perhaps most importantly from the standpoint of thepresent invention, on leads of cardiac pacemakers. An early version of thereinforced elastomer used as insulators on implantable devices, primarily pacemakers,was known in the trade as Dow Corning MDX4-4516. A later version was known asDow Corning HP (high performance) material. The early version (MDX4—45 16)consisted of silica reinforced polydimethylsiloxane which included approximately0.142 mol per cent methylvinylsiloxane [(CH3)(CH2=CH)Si-O] units. The endblocking (terminal) units of this early version of the polymer weredimethylvinylsiloxane units [(CH3)2(CH2=CH)Si-O]. Based on the presence ofapproximately 0.142 mol percent of methylvinylsiloxane units in this prior art1015202530W0 98/10433CA 02264139 l999-02- l7PCTIU S97/ 148042polymer, it can be calculated that approximately 750 dimethylsiloxane [(CH3);,_SiO]units are disposed on the average between each "pendant" vinyl group in thepolysiloxane chain. The vinyl groups in the polymer participate in a cross-linkingreaction which occurs in the final curing step when the polymer is formed into adesired shape, such as a single or multi-lumen tubular object. The curing or cross-linking step was initiated by addition of a peroxide catalyst or catalysts. The fillermaterial of this earlier version was silica that had been treated with dimethylsiloxaneoligomer.The later, high performance version of the prior art silicone elastomer (DowCorning HP) used as leads in implantable medical devices, primarily pacemakers,consisted of a blend of a first (major) and a second (minor) polysiloxane composition.The first and major composition comprised approximately 80 - 90 per cent (byweight) of the blend, and this composition contained no pendant vinyl or otherpendant olefinic groups. The second and minor composition comprised the balanceof the blend (before reinforcing treated silica was added), and had approximately 2mol percent methylvinylsiloxane [(CH3)(CH2=CH)Si-O] units and was alsoterminated with dimethylvinylsiloxane [(CH3)2(CH;,_=CH)Si-O] units. The reinforcingmaterial was silica that had been treated with a reagent that introduced trimethylsilylgroups into the material, thereby replacing OH functions with OSi(CH3)3 functionsand rendering the treated silica compatible with the "hydrophobic" silicone polymer.The curing or cross-linking step was initiated by addition of a platinum catalyst orcatalysts.As it will be readily appreciated by those skilled in the art, certain mechanicalproperties, such as tear strength, abrasion resistance, resistance to shredding,compression set, crush and creep resistance are of great importance in the materialsfor electrical leads in any device that is implanted into the human body, andparticularly so for insulators of cardiac pacemakers. It should also be readilyappreciated by those skilled in the art that improved mechanical properties, andparticularly improved compression set, creep and crush resistance allow themanufacture of insulated electrical leads of smaller dimensions and therefore10152025W0 98/ 10433CA 02264139 l999-02- l7PCT/US97/14804facilitates "downsizing" of the implantable device. Whereas the later version (DowCorning HP) of the above-summarized prior art silicone elastomers had certainimproved mechanical properties (for example improved tear strength) relative to theearlier MDX4-4516 version, it was then surprising to the artisans in the field that thisotherwise improved material had less crush resistance than the earlier MDX4-4516material. Therefore, up to the present invention the prior art struggled with theproblem that neither of the two types of silicone elastomeric materials available forforming insulators for cardiac pacemaker and similar implantable leads had optimalcharacteristics. As noted above, the earlier version could have used improvement inseveral mechanical properties, and the later version had improved mechanicalproperties in virtually all aspects, but had less crush resistance than the earlier version. ~In light of the foregoing, up to the present invention the need still existedinthe prior art for a polysiloxane elastomer material which is suitable for use as insulatorfor leads of implantable electrical devices, particularly cardiac pacemakers, and whichhas improved overall mechanical properties, including improved compression set, andimproved crush and creep resistance. The present invention provides such a material.SUMMARY OF THE INVENTIONIt is an object of the present invention to provide a silicone elastomer materialwhich is suitable for forming insulation for electrical leads of implantable medicaldevices, and which has improved overall mechanical properties.It is another object of the present invention to provide insulating single-lumenor multi-lumen tubular material for electrical leads of implantable medical devices,especially cardiac pacemakers, which material has improved overall mechanicalproperties, including improved compression set, and improved crush resistance.The foregoing and other objects of the present invention are attained by anelastomer composition that, before a cross-linking step of final curing, essentiallyconsists of the following materials:approximately 23 to 45 percent by weight of silica that had been silyliated bytreatment;1015202530W0 98/10433CA 02264139 l999-02- l7PCT/US97/148044the balance of the composition being a polysiloxane copolymer composed ofdivalent -R,R2SiO-, divalent -R2R4SiO- and monovalent (terminal, or end-blocking)R5R6R7SiO- units,where R] and R2 independantly are lower alkyl of 1 to 6 carbons, phenyl ortrifluoropropyl,R3 is vinyl, allyl, or other olefinic group having up to 4 carbons, R4 is loweralkyl of 1 to 6 carbons, phenyl or trifluoropropyl, andR5, R6, and R7 independantly are lower alkyl of 1 to 6 carbons, phenyl, vinyl,allyl, or other olefinic‘ group having up to 4 carbons.The above—described polysiloxane copolymer has a degree of polymerization(D. P.) approximately in the range of 3500 to 6500, and the olefin containing -R3R4SiO- groups are randomly distributed in the copolymer and are presentapproximately in the 0.05 to 0.3 mol percent range. The balance of the polysiloxanecopolymer composition is made up of the above noted divalent -R,R2SiO- siloxaneunits, and of the end-blocking R5R6R7SiO- units. However, to the extent R, , or R2 ,or both may represent phenyl groups, the proportion of the phenyl-containing divalentsiloxane units does not exceed 15 mol per cent. To the extent R1 or R2 representstrifluoropropyl groups, the proportion of the trifluoropropyl-containing divalentsiloxane units does not exceed approximately 40 mol per cent in the polysiloxanecopolymer of the invention. In such situations in the balance of the -R1R2SiO-siloxane units the substituents are neither phenyl, nor trifluoropropyl substituted,respectively.Those skilled in the art will readily understand that the proportion of the end-blocking R5R6R7SiO- units, as expressed in mol percentage, is determined by thedegree of polymerization: when the degree of polymerization is 5000, the endblocking groups are present as 2/5000 mol per cent. HThe above—described composition undergoes a cross-linking or "final curing"step after a platinum catalyst, an organohydrogen polysiloxane cross-linker and asuitable inhibitor are added. The composition that exhibits the desired improvedmechanical/physical properties is a result of the cross-linking or final curing reaction.1O15202530CA 02264139 2001-05-1866742~69OIn the cured composition covalently linked intermolecular andintramolecular ethylenic (-CH2—CH2-) bridges are formed fromsome of the olefin groups of the polysiloxane copolymer. Theimproved mechanical/physical properties include high tear,abrasion creep and crush resistance, and improved compressionset. The cured silicone material is resistant to crackinitiation under compressive loading. The objects consistingof the composition if the present invention, such as the singleor multi—lumen tubes that are used as insulators for leads ofcardiac pacemakers (or of other implantable medical devices)can be formed by means known in the art, such as extrusion ormolding. The final curing step occurs when the composition hasalready been formed into substantially the desired shape.According to one aspect of the present invention,there is provided an electrical lead comprising a conductor andan exterior insulator covering at least a portion of theconductor, the insulator consisting essentially of a curedelastomer composition obtained by cross—linking an uncuredblend composition that comprises an intimately admixed mixturethat includes the following components: (1) silica that hadbeen silyliated by treatment and contains trialkylsilyl groups,comprising approximately 23 to 45 percent by weight of themixture; (2) a polysiloxane copolymer composed of divalent—RflQSiO-, divalent —RfihSiO— and end—blocking RfiQR7SiO— units,the polysiloxane copolymer comprising approximately 55 to 77per cent by weight of the mixture; where R1 and R2 independantlyare lower alkyl of 1 to 6 carbons, phenyl or trifluoropropyl,R3, is vinyl, allyl, or other olefinic group having up to 4carbons, R4 is lower alkyl of 1 to 6 carbons, phenyl ortrifluoropropyl, and R5, R6, and R7 independantly are lower1O15202530CA 02264139 2001-05-1866742-6905aalkyl of 1 to 6 carbons, phenyl, vinyl, allyl, or otherolefinic group having up to 4 carbons, (3) a catalyst, and (4)a cross—linker, the catalyst and the cross—linker being presentin the uncured blend composition in sufficient amount to causethe cross—linking reaction to occur.According to another aspect of the present invention,there is provided a cured elastomer composition obtained bycross—linking an uncured blend composition that comprises anintimately admixed mixture that includes the followingcomponents: (1) silica that has been silyliated by treatmentand contains trialkylsilyl groups, comprising approximately 23to 45 percent by weight of the mixture; (2) a polysiloxanecopolymer composed of divalent —RfiQSiO—, divalent —RflhSiO- andend blocking RfiQRqSiO~ units, the polysiloxane copolymercomprising approximately 55 to 77 percent by weight of thewhere R1 and R2 independantly are lower alkyl of 1 to 6allyl,mixture;carbons, phenyl or trifluoropropyl, R3 is vinyl, or otherolefinic group having up to 4 carbons, R4 is lower alkyl of 1 to6 carbons, phenyl or trifluoropropyl, and Re Rsand R7independantly are lower alkyl of 1 to 6 carbons, phenyl, vinyl,allyl, or other olefinic group having up to 4 carbons, (3) acatalyst, and (4) a cross—linker, the catalyst and the cross-linker being present in the uncured blend composition insufficient amount to cause the cross—linking reaction to occur.According to still another aspect of the presentinvention, there is provided an uncured elastomer blendcomposition suitable for curing by cross—linking, thecomposition comprising two aliquots in combination: the firstaliquot comprising an intimately admixed mixture of thefollowing components: (1) silica that has been silyliated bytreatment and contains trialkylsilyl groups, comprisingapproximately 23 to 45 percent by weight of the mixture; (2) apolysiloxane copolymer composed of divalent —RfiQSiO—, divalentl0152025CA 02264139 2001-05-1866742-6905b—RfiQSiO— and end blocking RfiQRqSiO— units, the polysiloxanecopolymer comprising approximately 55 to 77 percent by weightof the mixture; where R1 and R2 independantly are lower alkyl of1 to 6 carbons, phenyl or trifluoropropyl, R3 is vinyl, allyl,or other olefinic group having up to 4 carbons, R4 is loweralkyl of 1 to 6 carbons, phenyl or trifluoropropyl, and RSREand R7 independantly are lower alkyl of 1 to 6 carbons, phenyl,vinyl, allyl, or other olefinic group having up to 4 carbons,and (3) a catalyst, the second aliquot comprising an intimatelyadmixed mixture of the following components: (1) approximately23 to 45 percent by weight of silica that had been silyliatedby treatment and contains trialkylsilyl groups; (2)approximately 55 to 77 percent by weight of a polysiloxanecopolymer composed of divalent —RfiQSiO—, divalent —RfihSiO— andend blocking R5R&hSiO— units, where R; and R2 independantly arelower alkyl of 1 to 6 carbons, phenyl or trifluoropropyl, R3 isvinyl, allyl, or other olefinic group having up to 4 carbons, R4is lower alkyl of 1 to 6 carbons, phenyl, or trifluoropropyl,and R& R5, and R7 independantly are lower alkyl of 1 to 6carbons, phenyl, vinyl, allyl, or other olefinic group havingup to 4 carbons, and (3) a cross—linker, the catalyst and thecross—linker being present in the first and second aliquotsrespectively in sufficient amounts to cause the cross—linkingreaction to occur after the first and second aliquots areintimately mixed.The features of the present invention can be bestunderstood together with further objects and advantages byreference to the following description, taken in connectionwith the accompanying drawing.101520CA 02264139 2001-05-1866742-6905cBRIEF DESCRIPTION OF THE FIGURESFIG. I is a plan view of a medical electrical leadsystem suitable for endocardial stimulation by an implantableheart pacemaker.FIG. la is a cross—sectional view of a lead assemblyportion of the lead system of FIG. 1FIG. 2 is a schematic showing of an extrusion linefor manufacturing thin walled medical tubing of siliconeelastomer.The drawings are not necessarily to scale.DETAILED DESCRIPTION OF THE INVENTIONReinforced elastomeric compositions are provided inaccordance with the present invention which after curing bycross—linking are suitable for use as insulators for electricalleads, and particularly as insulators for medical electricalleads, especially cardiac pacemaker leads.In a preferred embodiment of the present invention, amedical electrical lead which features a reinforced elastomericcomposition comprises an electrode at a distal end thereof, aconnector at a proximal end thereof and an elongated electricalconductor extending between the electrode and the connector,the conductor in1015202530W0 98/ 10433CA 02264139 l999-02- l7PCT/US97/148046electrical contact with the electrode at a distal end and in electrical contact with theconnector at a proximal end, the conductor comprised of a plurality of wires or wirebundles wound in a multifilar coil configuration.Referring now to the drawings, FIG. 1 shows a lead system 10 which includesa lead assembly 15, an anchoring sleeve 20, a connector 25, a stylet guide 30, and astiffening stylet 35. As is well known in the art, once implanted stylet guide 30, and astiffening stylet 35 are removed from lead.Referring now to FIG. 1a, the lead assembly 15 is shown in greater detail withan electrode structure 40 at a distal end of the lead assembly 15, a tine 45 to secure thelead assembly 15 to the endocardium, a lead conductor 50 in a multifilar coilconfiguration which allows the stiffening stylet 35 to be inserted into the lead ‘assembly 15 in the internal lumen 52 of the lead conductor 50. The lead conductor 50is shown attached at its distal end 55 to the electrode structure 40. The lead conductor50 is also similarly attached at a proximal end (not shown) to the connector 25. In thepreferred embodiment conductor 50 is a multifilar coil. Insulation elements 57a, 57band 570 insulate portions of the electrode structure 40 and the lead conductor 50. Suchinsulation elements 57a, 57b, and 57c are preferably made from any of the reinforcedpolysiloxane elastomer compositions already described above. The insulator 57c istypically a hollow polymeric tube extending between the proximal and distal ends ofthe lead assembly 15 and insulating the lead conductor 50 from surrounding bodytissues. Housed within insulator at the distal end is a monolithic controlled device 99to elute an anti-inflamrnatory agent, as is well known in the art. While a unipolar leadis shown, and described above, the present invention can also be applied to bipolarleads in the same manner. As used in implantable pacing leads, the individual wires ofthe lead conductor 50 would be typically about 0.004 to 0.010 in diameter and wouldbe wound into extremely small coils; typically having a diameter of less than 23 turn.Turning now to the elastomeric composition of the present invention, beforefinal curing or cross-linking, includes a polysiloxane copolymer that has the followingcomposition and characteristics. The polysiloxane copolymer has a degree ofpolymerization of approximately 3500 to 6500, with a D. P of approximately 50001015202530W0 98/ 10433CA 02264139 l999-02- l7PCT/US97/148047being preferred. Those skilled in the art will readily understand that the actual extentor degree of polymerization of a polysiloxane product is very difficult, if notimpossible, to measure. Therefore, the "degree of polymerization“ normally used inthe art to characterize a polysiloxane product is usually based on theoreticalconsiderations and measurements which measure a physical characteristic (such asplasticity) that is related to D. P. Therefore, in accordance with usual practice in theart the designated degree of polymerization of a polysiloxane material is that whichwould be normally expected based on the materials and conditions used in thepolymerization reaction and on measurements of certain characteristics, such asplasticity.The polysiloxane copolymer includes divalent -R1R2SiO- and divalent -R3R4SiO- units where the R, and R2 groups independantly are lower alkyl of 1 to 6carbons, phenyl or trifluoropropyl. Preferably, the R, and R2 groups both are methyl.Therefore in the preferred embodiment of the composition of the invention the -R,R2SiO- unit represents dimethylsiloxane [(CH3)2SiO].R3 is vinyl, allyl, or other olefinic group having up to 4 carbons, and R4 islower alkyl of 1 to 6 carbons, phenyl or trifluoropropyl. Preferably the R3 group isvinyl and the R4 group is methyl. Therefore in the preferred embodiment of thecomposition of the invention the -R3R4SiO- groups represents methylvinylsiloxane[CH3(CH2=CH)SiO]. The presence of the vinyl (or other olefinic group designatedR3) is important for the present invention because these "pendant" vinyl (all otherolefinic) groups enable the cross-linking reaction which occurs during final curing,and which is described later. The -R3R4SiO— groups, or more preferably themethylvinylsiloxane groups, are present in the range of approximately 0.05 to 0.3 molpercent, preferably approximately 0.142 mol per cent. Except for the end-blockinggroups described below, the balance of the polysiloxane copolymer consists of the -R1R2SiO—, preferably dimethylsiloxane, groups which thus form the backbone or bulkof the polysiloxane chain.The nature of the end-blocking or terminal groups R5R6R7SiO- is less criticalfrom the standpoint of the present invention than in the prior art. The R5, R6, and R71015202530W0 98/10433CA 02264139 l999-02- l7PCT/U S97/ 148048groups independantly are lower alkyl of l to 6 carbons, phenyl, vinyl, allyl, or otherolefinic group having up to 4 carbons. It is noteworthy, that unlike in the prior art theend-blocking group does not need to necessarily include a vinyl or other olefinicgroup, although in the preferred embodiment the end blocking group isdimethylvinylsiloxane [(CH3)2(CH=CH2)SiO]. The proportion (expressed in molpercent) of the end-blocking groups relative to the entire polysiloxane copolymer isdetermined by the degree of polymerization of the substance. With a preferred D. P.of 5000, the mol percent of the end blocking groups is 2/5000. Because the range ofD. P. of the polysiloxane copolymer is approximately3500 to 6500 in accordance with the invention, the mol percentage of the endblocking groups is in the range of approximately 2/6500 to 2/3500 (approximately0.00031 to 0.0006 mol percent).It follows from the foregoing data that the mol percentage of the -R,R2SiO-,preferably dimethylsiloxane, groups in accordance with the invention groups(calculated to two decimal points) is in the range of approximately 99.7 to 99.95 molpercent. However when the R1 or R2 symbols, or both, represent phenyl groupsthen the proportion of the phenyl—containing divalent siloxane units does not exceed15 mol per cent, the balance of the -R1R2SiO- groups do not include a phenyl group.A similar restriction of approximately 40 mol per cent applies when the R1R2SiO—group includes trifluoropropyl.The above described composition of the polysiloxane copolymer is novel andsurprising especially in terms of the mechanical properties achieved. This is because,as is noted in the description of the prior art, the prior art MDX4-4516 copolymerhaving "pendant" vinyl groups lacked somewhat in mechanical properties such as tearresistance. The other prior art HP product which had pendant vinyl groups only in aminor component of two blended copolymers, had improved tear resistance butdecreased crush resistance. Therefore, it is surprising that the present compositionthat includes pendant vinyl groups in the single and therefore major macromolecularcomponent of the elastomer, has increased compression set, and improved creep,crush and abrasion resistance.1015202530W0 98/10433CA 02264139 l999-02- l7PCT/US97/ 148049Another major component of the elastomeric composition of the presentinvention is silyliated silica that acts as a reinforcer in the composition. Blendingsilyliated "fumed silica" into a polysiloxane copolymer as a "reinforcer" and toimprove its mechanical properties, per se is not new in the art. In accordance with thepresent invention the fume silica used as a reinforcer is treated with a reagent thatintroduces trialkylsilyl groups (alkyl has 1 to 6 carbons, preferably 1 to 2) to thesurface of the silica so that a plurality of OH functions on the surface becomeO(trialkylsilyl) functions. Preferably, trimethylsilyl groups are introduced into thesilica used in the composition of the present invention. The silica used in the presentinvention has a relatively small surface area, as this term is understood in the art,nevertheless the surface area should be at least approximately 200 meter2/ gram of theyet not silyliated silica. The silyliation, preferably introduction of trimethylsilylgroups, can be accomplished before the silica is admixed or blended with thepolysiloxane copolymer that has been described above. Alternatively, the silyliationof the silica may be performed as part of the blending process of the copolymer withthe silica. In the preparation of the preferred embodiment of the elastomer of thepresent invention the latter procedure is preferred. In any event, the degree ofsilyliation is normally measured in the art by expressing the carbon content of thesilyliated silica. (As is known, the carbon content can be readily determinedanalytically, for example by combustion analysis.) In accordance with the presentinvention the carbon content of the trimethyl silyl groups containing silica should bein the range of approximately 4 to 8 per cent by weight of the silyliated silica, andpreferably approximately 7.3 per cent by weight. The amount of treated(trimethylsilyliated) silica used in the composition is in the range of approximately 23to 45 per cent by weight of the composition, with approximately 39 per cent byweight being preferred.The elastomeric composition which is the result of blending treated silica andthe above-described polysiloxane copolymer together is not cross linked (not yetcured or vulcanized) and therefore does not yet have the desired physical/mechanicalproperties. Nevertheless this blend or composition (sometimes referred to as the1015202530WO 98110433CA 02264139 l999-02- l7PCT/US97/1480410"base") itself is considered innovative and useful because it serves as a precursor tothe cured elastomer that has the advantageous mechanical properties. Thus theuncured composition or base has the inherent characteristics of providing, aftersuitable vulcanization by cross-linking, a material that can be shaped to form tubularinsulators for pacemaker leads, having excellent mechanical properties.Normally the final curing and vulcanization step is performed only after theblend or composition is shaped into the desired object (for example by extrusion ormolding) and this step of fabrication and vulcanization is normally performed atlocations different than where the manufacture of the blend occurs. For these reasons,in accordance with standard practice in the art, the blend composition or base isdivided into two substantially equal weight and volume aliquots, designated "Part A"and "Part B". Suitable catalyst to catalyze the cross-linking reaction is added to oneof the aliquots (Part A), and a cross-linking agent and a cross-linking inhibitor isadded to Part B. The two parts are kept and transported separately and are intimatelymixed together just prior to fabrication of the desired object. The amounts ofcatalyst, cross-linking agent and inhibitor are "fine tuned" in the preferredembodiment of the present invention to provide appropriate time for the fabrication ofinsulators for cardiac pacemaker leads and similar objects.As is known in the art, the cross-linking (curing or vulcanization step) is theresult of a platinum catalyzed reaction between a silicon bonded "pendant" and/orterminal vinyl (or other olefinic group) and a silicon bonded hydrogen group. Thevinyl (or other olefinic) group is present in the polysiloxane composition even beforeit is divided into Parts A and Parts B. The silicon bonded hydrogen group is presentin the blend of the two parts because it is added to Part B in the form of a cross-linking agent. In the actual cross-linking reaction ethylenic (-CH2-CH2-) bridges areformed by saturating vinyl groups and linking one polymer molecule to a silicon atomof a cross-linking molecule, which is in turn linked by yet another ethylenic bridge(by saturating another vinyl group) to another polymer molecule. In essence thechemical reaction, which is per se known in the art, involves saturation of a vinyl (orother unsaturated) group of an R3R4SiO unit and/or of a terminal R5R6R7SiO unitlO1.5202530CA 02264139 2001-05-1866742-6901.1with the hydrogen derived from an at least difunctionalorganohydrogen polysiloxane, and formation of carbon to siliconbonds and thereby bridges between the several polysiloxanemolecules.More specifically, the platinum catalyst can beselected, within the skill of the art, primarily from organoplatinum compounds, for example in accordance with UnitedStates Patent Nos. 2,823,218 and 3,159,601. The platinumcatalyst is added to Part A in amounts of approximately 6 to 30parts per million as platinum, with the result that in theblend of Part A and Part B which is to be vulcanized or curedthe platinum is present in the proportion of approximately 3 to15 part per million per weight.Although, as noted above the platinum catalyst can beselected within the skill of the art, in the preferredembodiment a platinum catalyst is used which is the result ofcomplexing tetramethyldivinyldisiloxane with hexachloroplatinicacid pentahydrate, and this complex is added to Part A in the(ppm) per weight asA number of cross—linking agentsproportion of 10 to 24 part per millionplatinum, preferably 20 ppm.are suitable for the practice of the present invention and canbe selected by those familiar with the art. United StatesPatent No. 3,436,366 describes a number of cross—linkingagents. Thus, the liquid organohydrogen polysiloxane cross-linkers shown in Column 2 of the above noted United States(R) a (H) bSiO2—a/2—b/2where R is simple lower alkyl and “a” ranges from 1.00 to 3,“bl!Patent No. 3,436,366 and having the formulaand ranges from 0.1 to 1.0 are particularly satisfactoryfor use in the present invention. Especially suitable is thecross—linker of Column 4, lines 3-14 of the ‘366 patent whichhas the formula R2HSiO1fl where the R groups are primarily orpredominantly methyl. The cross—linking agent is added to thesecond aliquot (Part B) of the composition in the proportion ofCA 02264139 2001-05-1866742-690llaapproximately 2 to 6 parts per hundred per weight of Part B.Consequently in the blend of Part A and Part B which is to bevulcanized or cured the cross—linking agent is present in theratio of approximately 1 to 3 parts per hundred per weight.1015202530WO 98/10433CA 02264139 l999-02- l7PCT/U S97/ 1480412It is important in accordance with the present invention that, after mixing thealiquots (Parts A and B) the cross-linking reaction not proceed too rapidly at roomtemperature, allowing at least a few hours and even up to 6 — 8 hours for work timewith the mixed aliquots. For this reason one or more suitable inhibitors of the cross-linking reaction are also added to the mixture. Preferably the inhibitor is added to thePart B aliquot. Suitable inhibitors may be readily selected within the skill of the art.One example of such an inhibitor is 1,2,3,4-tetramethyl-1,2,3,4-tetravinylcyclotetrasiloxane, another is 1-ethynyl-1-cyclohexanol. The ethynylcyclohexanolinhibitor is added to Part B in the range of approximately 0.01 to 0.2 parts perhundred parts of Part B, by weight. Therefore it is present in the mixed aliquotsito becured or vulcanized in the range of 0.005 to 0.1 part per hundred, per weight. This.inhibitor, being volatile, can be driven off by heat in a final curing step, thus allowingthe cross-linking reaction to occur rapidly. Other less-volatile or non-volatileinhibitors may be used instead, the amount of these would be adjusted such that thecross-linking reaction should nevertheless occur in the desired time frame after Part Aand Part B are mixed.Addition of catalyst, cross-linker and inhibitor in the above—noted rangesusually serves to provide approximately 6 - 8 hours of work time at room temperature.This means that the material does not cure significantly at room temperature within 6 -8 hours. Before curing and cross-linking the two aliquots are intimately mixedpreferably in equal amounts.The process of manufacturing the cured reinforced polysiloxane objects, whichcan serve as insulators for leads of cardiac pacemakers or other devices, starting withthe preparation of the preferred embodiment of the polysiloxane copolymer, thusproceeds as follows.In a suitable reactor octamethylcyclotetrasiloxane (precursor to the -R,R2SiO-groups of the copolymer) and tetravinyltetramethylcyclotetrasiloxane (precursor to the-R3R4SiO- groups of the copolymer) are mixed and heated until a temperature of 150 °C is reached, and the mixture is stirred at that temperature for approximately 1 hour.Then the end blocker (precursor to the R5R6R7SiO- units of the copolymer) is added1015202530W0 98/ 10433CA 02264139 l999-02- l7PCT/U S97/ 1480413together with a catalyst. The end blocking reagent or material can betetramethyldivinyldisiloxane, and the catalyst can be acid or base catalyst normallyutilized in the art for siloxane polymerization reactions, as is described for example inUnited States Patent No. 3,779,987 incorporated herein by reference. Preferably,however the end blocking reagent is a product which results from the reaction(equilibration) of tetramethyldivinyldisiloxane with octamethylcylcotetrasiloxaneunits. The catalyst is preferably potassium siloxanolate which per se is known in theart. After the end blocking reagent and the catalyst are added, heating is continuedonly for a short time, whereafter the catalyst is neutralized. In case of potassiumsiloxanolate the catalyst is neutralized by introducing carbon dioxide into the mixture.Although as it was noted above the degree of polymerization per se is hard orimpossible to measure, plasticity is related to D. P. and can be measured in the routinetest known as ASTM 926 "Rubber Property-Plastics and Recovery (parallel platemethod). The polymerization reaction can thus be monitored by this test. At the endof the polymerization (corresponding to a desired theoretical D. P. of approximately5000) the plasticity should be approximately 55, with a range of 50 to 60 beingacceptable. The just described polymerization reaction provides the polysiloxanecopolymer component of the elastomer of the present invention.The polymer is subjected to vacuum to remove volatile materials, and isthereafter mixed with the requisite amount of silica. As it was noted above, in theprocess preferred for making the elastomer of the present invention, the silica issilyliated substantially in the same process where it is blended with the polysiloxanecopolymer. Thus, in the preferred process silica having a surface area of at least 200m2/gram is slowly blended under an inert gas blanket into the polysiloxane copolymerobtained above, together with water and the silyliating agent hexamethyldisilazine[(CH3)3Si-N(H)-Si(CH3)3 ]. The mixture is heated first under the blanket of inert gas,and thereafter in vacuum to remove volatile materials. The resulting silica reinforcedpolysiloxane copolymer composition is sometimes referred to as the "base". It is thiscomposition or base which is divided into the aliquots called Part A and Part B. Thecatalyst, cross-linking agent and inhibitor are added to Part A and Part B, respectively1015'202530W0 98/ 10433CA 02264139 l999-02- l7PCT/US97/ 1480414by intimate mixing, for example on a two roll mill, followed by passing the mixturethrough fine stainless steel mesh screens. Typical mesh size is generally in the rangeof 200 to 500, preferably approximately 400 mesh.Fabrication of objects from the two aliquots is accomplished by intimatelymixing equal or substantially equal volumes and weights of the aliquots and thenshaping the mixture into the desired form, before the cross-linking or curing reactionis substantially completed. The cross-linking reaction can be accelerated by placingthe shaped object into a hot air vulcanizing chamber where a volatile inhibitor isdriven off, thereby allowing the cross-linking reaction to occur rapidly.Generally speaking, Parts A and B are mixed on a two roll mill which providesthe blended base where the curing is inhibited due to presence of the inhibitor. Theblended base is then extruded through standard extrusion techniques which are per seknown in the art, and are illustrated in the FIG. 2. Thus the mixed aliquots (blendedParts A and B) are placed into the extruder device 100. A typical tubing line alsoincludes a die 120, a curing or vulcanizing oven 140, and a puller winder device 160on which the extruded tubing is taken up or coiled. The die 120 preferably includesan internal mandrel (not shown) as is well known in the art. To obtain precisedimensions such as may be necessary with small thin-wall medical tubing, a gearpump (not shown) may be used at the extruder discharge for stable throughput. Gearpumps are calibrated to forward precise metered amounts of polymer. Their use inthis manner is well known. After the tubing is formed by extrusion it is placed into ahot air vulcanizing chamber where the volatile inhibitor (ethynylcyclohexanol) isdriven off, thereby allowing the cross-linking reaction to proceed to yield the finalproduct. The preferred method for mixing Parts A and B, before shaping the mixtureinto insulators for leads of implantable medical devices by extrusion is described inmore detail below as a specific example.A creep evaluation test was performed on the preferred embodiment of thecured elastomer composition of the present invention which has been shaped into theform of tubing, in accordance with ASTM D 2990 Standard Test Methods for Tensile,Compression, and Flexural Creep and Creep Rupture of Plastics. For comparison the1015202530WO 98/10433CA 02264139 l999-02- l7PCT/US97/1480415same tests were also perfonned on the prior art materials discussed in the introductorysection of this application, namely on MDX4-4516 and on the HP material. Thepercentage of initial elongation upon loading was the highest for the prior artMDX4—45l6 material (approximately 225 %) less for the HP material (approximately150 %), and still less for the preferred embodiment (approximately 110 %), Percentelongation upon loading changed in time the most (the slope of the elongation versustime curve was the largest) with the HP material, less with the MDX4-4516 material,and the least with the preferred embodiment of the present invention.Crush resistance testing was performed by dynamically compressing thesilicone tubing under a defined consistent per cent compression relative to the cross-sectional width of the tubing. The cycles of the compression were measured andrecorded until the tubing split. All tubings in these tests had the same inner and outerdiameters and wall thickness. In these tests the prior art HP material split afterapproximately 500 cycles (least crush resistant), and the prior art MDX4-4516material split after 1500 cycles. The preferred embodiment of the invention split onlyafter 2800 cycles, which represent a 460 % increase over the HP material, and still asignificant 86.6 % increase over the MDX4-4516 material.SPECIFIC EXAMPLEPreparation of Base PolymerIn a 150 gallon suitable mixer, mix octamethylcyclotetrasiloxane (300.0 kg)and tetramethyltetravinylcyclotetrasiloxane (0.50 kg) and heat to 150 C-with agitationunder a nitrogen blanket. Hold at 150 C for one hour. After one hour add pre-equilibrated vinyldimethyl-terminated siloxane oligomer (450.0 grams) as end-blockerand 0.001 percent (by weight) of potassium siloxanolate catalyst (about 300 grams).Continue heating and stirring until polymerization is completed. (about 3 min). Aftercompletion of the polymerization the catalyst is then neutralized or destroyed bybubbling CO2 through the polymer while continuing mixing. At this time the polymeris devolatilized by pulling a full vacuum on the mixer. Continue the vacuum for onehour while continuing to bubble CO2 through the polymer. After one hour, stop thevacuum, stop CO2 flow, vent the mixer with N2, and allow to cool.1015202530WO 98/10433CA 02264139 l999-02- l7PCT/U S97/ 1480416Formulation of Base Including Silica ReinforcerIn a 50 gallon, Sigma blade mixer, mix the above polymer (90.0 kg) withhexamethyldisilizane (8.06 kg) and water (2.30 kg). Blanket the mixer with N2. Addadequate fumed silica to fill the mixer. Mix until the polymer and silica has massed.Continue in this manner until the total amount of silica has been added (57.6 kg).After the final silica addition has massed, bring the base to 80 C and hold at thistemperature for 30 minutes. After 30 minutes, stop N2 flow, turn on vacuum to mixer,and begin heating to 180 C. Continue mixing for three hours after temperaturereaches 180 C while maintaining full vacuum. After three hours, vent mixer with N2and allow to cool.Preparation of Parts A and BThe base is now divided into two equal parts. One of the two parts is nowsoftened on a two roll mill. After softening, a platinum complex catalyst is added viatwo roll milling such that the resulting Part A contains 10-24 ppm platinum, typically20 ppm. Using a screw type extruder, the Part A is passed through fine stainless steelmesh screens. Mesh size is generally 200-500, typically 400 mesh. The second halfof the base is similarly softened. After softening, both cross-linker and inhibitor areadded via two roll milling. The siloxane cross-linker, a copolymer consisting of bothdimethyl and methylhydrogen monomers, is added at 2-4 parts per hundred (pph) byweight, and typically 3.0 pph. Similarly the inhibitor, generally an acetylinic alcoholsuch as 1-ethynyl-1-cyclohexanol, is added at amounts up to 0.12 pph, typically at0.08 pph. The resulting Part B is now screened in a similar manner as Part A.Combination of Parts A and BParts A and B may then be combined and subjected to forming as alreadydescribed above.The Examples and disclosure are intended to be illustrative and not exhaustive.These examples and description will suggest many variations and alternatives to oneof ordinary skill in this art. All these alternatives and variations are intended to beincluded within the scope of the attached claims. Those familiar with the art mayrecognize other equivalents to the specific embodiments described herein which areCA 02264139 l999-02- 17WO 98/10433 » PCT/US97/1480417also intended to be within the scope of the invention. Therefore, the scope of thepresent invention should be interpreted solely from the following claims, as suchclaims are read in light of the disclosure.

Claims (38)

CLAIMS:

1. An electrical lead comprising a conductor and an exterior insulator covering at least a portion of the conductor, the insulator consisting essentially of a cured elastomer composition obtained by cross-linking an uncured blend composition that comprises an intimately admixed mixture that includes the following components:
(1) silica that had been silyliated by treatment and contains trialkylsilyl groups, comprising approximately 23 to 45 percent by weight of the mixture;
(2) a polysiloxane copolymer composed of divalent -R1R2SiO-, divalent -R3R4SiO- and end-blocking R5R6R7SiO- units, the polysiloxane copolymer comprising approximately 55 to 77 per cent by weight of the mixture;
where R1 and R2 independantly are lower alkyl of 1 to 6 carbons, phenyl or trifluoropropyl, R3, is vinyl, allyl, or other olefinic group having up to 4 carbons, R4 is lower alkyl of 1 to 6 carbons, phenyl or trifluoropropyl, and R5, R6, and R7, independantly are lower alkyl of 1 to 6 carbons, phenyl, vinyl, allyl, or other olefinic group having up to 4 carbons, (3) a catalyst, and (4) a cross-linker, the catalyst and the cross-linker being present in the uncured blend composition in sufficient amount to cause the cross-linking reaction to occur.

2. A lead according to claim 1 wherein the cross-linker is an organohydrogen polysiloxane.

3. A lead according to claim 1 or 2 wherein the polysiloxane copolymer has a degree of polymerization (D.P.) approximately in the range of 3500 to 6500.

4. A lead according to any one of claims 1 to 3 wherein R5, R6, and R7 independantly are lower alkyl of 1 to 6 carbons, phenyl, vinyl, allyl, or other olefinic group having up to 4 carbons and a double bond.

5. A lead according to any one of claims 1 to 4 wherein the olefin containing -R3R4SiO- groups are present randomly distributed in the polysiloxane copolymer and approximately in the 0.05 to 0.3 mol percent range, with the provisos that when R1 or R2, or both represent phenyl groups then proportion of the phenyl-containing divalent siloxane units does not exceed 15 mol percent and when R1 or R2 or both represent trifluoropropyl groups, then the proportion of the trifluoropropyl-containing divalent siloxane units does not exceed approximately 40 mol percent in the polysiloxane copolymer.

6. A lead according to claim 1 wherein in the polysiloxane copolymer the -R1R2SiO- group is -(CH3)2SiO-, the -R3R4SiO- group is -CH3 (CH2=CH) SiO-, and the R5R6R7SiO- group is - (CH3)2(CH2=CH)SiO-.

7. A lead according to claim 6 where the -CH3(CH2=CH)SiO-group is present in the polysiloxane copolymer in the proportion of 0.142 mol percent.

8. A lead according to any one of claims 1 to 7 where the silyliated silica includes trimethylsilyl groups in such quantity that the carbon content of the silica is in the range of approximately 4 to 8 percent by weight.

9. A lead according to claim 8 where the carbon content of the silyliated silica is approximately 7.3 percent by weight.

10. A lead according to any one of claims 1 to 9 where the insulator is a tube separately formed into which the conductor is inserted.

11. A lead according to claim 1 wherein the olefin containing -R3R4SiO- groups are present randomly distributed in the polysiloxane copolymer and approximately in the 0.05 to 0.3 mol percent range.

12. A lead according to claim 1, wherein R1, or R2, or both represent phenyl groups and the proportion of the phenyl-containing divalent siloxane units does not exceed 15 mol percent.

13. A lead according to claim 1, wherein R1 or R2, or both represent trifluoropropyl groups and the proportion of the trifluoropropyl-containing divalent siloxane units does not exceed approximately 40 mol percent in the polysiloxane copolymer.

14. A cured elastomer composition obtained by cross-linking an uncured blend composition that comprises an intimately admixed mixture that includes the following components:
(1) silica that has been silyliated by treatment and contains trialkylsilyl groups, comprising approximately 23 to 45 percent by weight of the mixture;
(2) a polysiloxane copolymer composed of divalent -R1R2SiO-, divalent -R3R4SiO- and end blocking R5R6R7SiO- units, the polysiloxane copolymer comprising approximately 55 to 77 percent by weight of the mixture;

where R1 and R2 independantly are lower alkyl of 1 to 6 carbons, phenyl or trifluoropropyl, R3 is vinyl, allyl, or other olefinic group having up to 4 carbons, R4 is lower alkyl of 1 to 6 carbons, phenyl or trifluoropropyl, and R5, R6 and R7 independantly are lower alkyl of 1 to 6 carbons, phenyl, vinyl, allyl, or other olefinic group having up to 4 carbons, (3) a catalyst, and (4) a cross-linker, the catalyst and the cross-linker being present in the uncured blend composition in sufficient amount to cause the cross-linking reaction to occur.

15. A cured elastomer composition according to claim 14 wherein the cross-linker is an organohydrogen polysiloxane.

16. A cured elastomer composition according to claim 14 or 15 wherein the polysiloxane copolymer has a degree of polymerization (D.P.) approximately in the range of 3500 to 6500.

17. A cured elastomer composition according to any one of claims 14 to 16 wherein R5R6, and R7 independantly are lower alkyl of 1 to 6 carbons, phenyl, vinyl, allyl, or other olefinic group having up to 4 carbons and a double bond.

18. A cured elastomer composition according to any one of claims 14 to 17 wherein the olefin containing -R3R4SiO- groups are present randomly distributed in the polysiloxane copolymer and approximately in the 0.05 to 0.3 mol percent range, with the provisos that when R1, or R2, or both represent phenyl groups then proportion of the phenyl-containing divalent siloxane units does not exceed 15 mol percent and when R1 or R2 or both represent trifluoropropyl groups, then the proportion of the trifluoropropyl-containing divalent siloxane units does not exceed approximately 40 mol percent in the polysiloxane copolymer.

19. A cured elastomer composition according to claim 14 wherein in the polysiloxane copolymer the -R1R2SiO- group is -(CH3)2SiO-, the -R3R4SiO- group is -CH3(CH2=CH)SiO-, and the R5R6R7SiO- group is -(CH3)2(CH2=CH)SiO-.

20. A cured elastomer composition according to claim 19 where the -CH3(CH2=CH)SiO- group is present in the polysiloxane copolymer in the proportion of 0.142 mol percent.

21. A cured elastomer composition according to any one of claims 14 to 20 silyliated silica includes trimethylsilyl groups in such quantity that the carbon content of the silica is in the range of approximately 4 to 8 percent by weight.

22. A cured elastomer composition according to claim 2 where the carbon content of the silyliated silica is approximately 7.3 percent by weight.

23. A cured elastomer composition according to claim 14 wherein the olefin containing -R3R4SiO- groups are present randomly distributed in the polysiloxane copolymer and approximately in the 0.05 to 0.3 mol percentage range.

24. A cured elastomer composition according to claim 14, wherein R1, or R2, or both represent phenyl groups and the proportion of the phenyl-containing divalent siloxane units does not exceed 15 mol percent.

25. A cured elastomer composition according to claim 14, wherein R1 or R2, or both represent trifluoropropyl groups and the proportion of the trifluoropropyl-containing divalent siloxane units does not exceed approximately 40 mol percent in the polysiloxane copolymer.

26. An uncured elastomer blend composition suitable for curing by cross-linking, the composition comprising two aliquots in combination:
the first aliquot comprising an intimately admixed mixture of the following components:
(1) silica that has been silyliated by treatment and contains trialkylsilyl groups, comprising approximately 23 to 45 percent by weight of the mixture;
(2) a polysiloxane copolymer composed of divalent -R1R2SiO-, divalent -R3R4SiO- and end-blocking R5R6R7SiO- units, the polysiloxane copolymer comprising approximately 55 to 77 percent by weight of the mixture;
where R1 and R2 independantly are lower alkyl of 1 to 6 carbons, phenyl or trifluoropropyl, R3 is vinyl, allyl, or other olefinic group having up to 4 carbons, R4 is lower alkyl of 1 to 6 carbons, phenyl or trifluoropropyl, and R5R6, and R7 independantly are lower alkyl of 1 to 6 carbons, phenyl, vinyl, allyl, or other olefinic group having up to 4 carbons, and (3) a catalyst, the second aliquot comprising an intimately admixed mixture of the following components:
(1) approximately 23 to 45 percent by weight of silica that had been silyliated by treatment and contains trialkylsilyl groups;
(2) approximately 55 to 77 percent by weight of a polysiloxane copolymer composed of divalent -R1R2SiO-, divalent -R3R4SiO- and end blocking R5R6R7SiO- units, where R1 and R2 independantly are lower alkyl of 1 to 6 carbons, phenyl or trifluoropropyl, R3 is vinyl, allyl, or other olefinic group having up to 4 carbons, R4 is lower alkyl of 1 to 6 carbons, phenyl, or trifluoropropyl, and R5, R6, and R7 independantly are lower alkyl of 1 to 6 carbons, phenyl, vinyl, allyl, or other olefinic group having up to 4 carbons, and (3) a cross-linker, the catalyst and the cross-linker being present in the first and second aliquots respectively in sufficient amounts to cause the cross-linking reaction to occur after the first and second aliquots are intimately mixed.

27. An uncured elastomer blend composition according to claim 26 wherein the cross-linker is an organohydrogen polysiloxane.

28. An uncured elastomer blend composition according to claim 26 or 27 wherein the polysiloxane copolymer of at least one aliquot has a degree of polymerization (D. P.) approximately in the range of 3500 to 6500.

29. An uncured elastomer blend composition according to any one of claims 26 to 28 wherein in at least one aliquot R5, R6, and R7 independantly are lower alkyl of 1 to 6 carbons, phenyl, vinyl, allyl, or other olefinic group having up to 4 carbons and a double bond.

30. An uncured elastomer blend composition according to any one of claims 26 to 29 wherein in at least one aliquot the olefin containing -R3R4SiO- groups are present randomly distributed in the polysiloxane copolymer and approximately in the 0.05 to 0.3 mol percent range, with the provisos that when R1, or R2, or both represent phenyl groups then proportion of the phenyl-containing divalent siloxane units does not exceed 15 mol percent and when R1 or R2, or both represent trifluoropropyl groups, then the proportion of the trifluoropropyl-containing divalent siloxane units does not exceed approximately 40 mol percent in the polysiloxane copolymer.

31. An uncured elastomer blend composition according to claim 26 wherein in the polysiloxane copolymer of at least one aliquot the -R1R2SiO- group is -(CH3)2SiO-, the -R3R4SiO- group is -CH3(CH2=CH)SiO- and the R5R6R7SiO- group is -(CH3)2(CH2=CH)SiO-.

32. An uncured elastomer blend composition according to claim 31 wherein said at least one aliquot the -CH3(CH2=CH)SiO
group is present in the polysiloxane copolymer in the proportion of 0.142 mol percent.

33. An uncured elastomer blend composition according to any one of claims 26 to 32 where the silyliated silica includes trimethylsilyl groups in such quantity that the carbon content of the silica is in the range of approximately 4 to 8 percent by weight.

34. An uncured elastomer blend composition according to claim 33 wherein at least one aliquot the carbon content of the silyliated silica is approximately 7.3 percent by weight.

35. An uncured elastomer blend composition according to claim 26 where in at least one aliquot the olefin containing -R3R4SiO- groups are present randomly distributed in the polysiloxane copolymer and approximately in the 0.05 to 0.3 mol percent range.

36. An uncured elastomer blend composition according to claim 26, wherein at least one aliquot R1 or R2, or both represent phenyl groups and the proportion of the phenyl-containing divalent siloxane units does not exceed 15 mol percent.

37. An uncured elastomer blend composition according to claim 26, wherein at least one aliquot R1 or R2 or both represent trifluoropropyl groups and the proportion of the trifluoropropyl-containing divalent siloxane units does not exceed approximately 40 mol percent in the polysiloxane copolymer.

38. The uncured elastomer blend composition of any of claims 26 - 37 wherein the second aliquot further comprises a volatile inhibitor in such quantity that the cross-linking reaction occurs rapidly after intimately mixing the first and second aliquots and substantially removing the inhibitor by heat.