Peroxide cross-linking and high temperature melting

Patent metadata

Field	Value
Publication number	US-10220547-B2
Application number	US-201415030206-A
Country	US
Kind code	B2
Filing date	Oct 16, 2014
Priority date	Oct 17, 2013
Publication date	Mar 5, 2019
Grant date	Mar 5, 2019

Abstract

Methods of making oxidation and wear resistant polymeric materials using peroxide cross-linking and high temperature melting process are disclosed. A multiple step procedure for enabling the manufacturing of such material without size limitations is also disclosed.

First claim

We claim:

1. A method of making a cross-linked polymeric material, wherein the method comprising the steps of:
a. blending a polymeric material with at least one antioxidant at a concentration that is between 0.05 wt % and 66.0 wt % and at least one cross-linking agent at a concentration that is between 0.5 and 66.5 wt %;
b. consolidating the blended polymeric material;
c. heating the consolidated polymeric material to a temperature that is about 200° C. or more for a period of time, wherein the heating step comprises:
i. heating the consolidated polymeric material to a temperature that is between about 200° C. and about 290° C.,
ii. maintaining the consolidated blended polymeric material at a temperature that is between about 200° C. and about 290° C.,
iii. heating the consolidated polymeric material to a temperature that is between about 290° C. and 350° C., and
iv. maintaining the consolidated blended polymeric material at a temperature that is between about 290° C. and 350° C. for at least 5 hours but no more than 30 hours; and

d. cooling the consolidated polymeric material, wherein the cooling step comprises:
i. permitting the heated consolidated blended polymeric material to cool to a temperature that is between about 135° C. and about 180° C.,
ii. maintaining the consolidated blended polymeric material at a temperature that is between about 135° C. and about 180° C., and
iii. permitting the consolidated blended polymeric material to cool to a temperature that is between about room temperature and 60° C.

2. The method according to claim 1 , wherein at least one antioxidant is vitamin E or Tetrakis[methylene(3,5-di-tert-butylhydroxyhydrocinnamate)] methane.

3. The method according to claim 1 , wherein at least one cross-linking agent is a peroxide, P130, a carbon-carbon initiator, 2,3-dimethyl-2,3-diphenylbutane, poly-1,4-diisopropylbenzene, or a mixture thereof.

4. The method according to claim 1 , wherein the heating after consolidation is done in inert gas.

5. The method according to claim 1 , wherein the heating after consolidation is done in air.

6. The method according to claim 1 , wherein the consolidation is carried out at a temperature that is between 150° C. and 210° C.

7. The method according to claim 1 , wherein the cross-linked polymeric material is further machined into a medical implant.

8. The method according to claim 1 , wherein the consolidation is done by ram extrusion.

9. The method according to claim 1 , wherein the antioxidant concentration is no more than 1.0 wt %.

10. The method according to claim 1 , wherein the cross-linking agent initiates cross-linking in the polymeric material.

11. A method of making an interlocked hybrid material, wherein the method comprising the steps of:
a. blending a polymeric material with at least one antioxidant at a concentration that is between 0.05 wt % and 66.0 wt % and at least one cross-linking agent at a concentration that is between 0.5 and 66.5 wt %;
b. layering the blended polymeric material and a second material;
c. consolidating the layers, thereby forming an interlocked hybrid material;
d. heating the interlocked hybrid material to a temperature that is above 200° C. for a period of time, wherein the heating step comprises:
i. heating the interlocked hybrid material to a temperature that is between about 200° C. and about 290° C.,
ii. maintaining the interlocked hybrid material at a temperature that is between about 200° C. and about 290° C.,
iii. heating the interlocked hybrid material to a temperature that is between about 290° C. and 350° C., and
iv. maintaining the interlocked hybrid material at a temperature that is between about 290° C. and 350° C. for at least 5 hours but no more than 30 hours: and

e. cooling the interlocked hybrid material, wherein the cooling step comprises:
i. permitting the heated interlocked hybrid material to cool to a temperature that is between about 135° C. and about 180° C.,
ii. maintaining the interlocked hybrid material at a temperature that is between about 135° C. and about 180° C., and
iii. permitting the interlocked hybrid material to cool to a temperature that is between about room temperature and 60° C.

12. The method according to claim 11 , wherein the second material is a porous metal.

13. The method according to claim 11 , wherein the interlocked hybrid material is consolidated in the form of a medical implant.

14. The method according to claim 11 , wherein the interlocked hybrid material is machined into a medical implant.

15. The method according to claim 11 , wherein the antioxidant concentration is no more than 1.0 wt %.

16. The method according to claim 11 , wherein the cross-linking agent initiates cross-linking in the polymeric material.

17. The method according to claim 11 , wherein the consolidation is carried out at a temperature that is between 150° C. and 210° C.

18. The method according to claim 11 , wherein at least one antioxidant is vitamin E or Tetrakis[methylene(3,5-di-tert-butylhydroxyhydrocinnamate)]methane.

19. The method according to claim 11 , wherein at least one cross-linking agent is a peroxide, P130, a carbon-carbon initiator, 2,3-dimethyl-2,3-diphenylbutane, poly-1,4-diisopropylbenzene, or a mixture thereof.

20. The method according to claim 11 , wherein the heating after consolidation is done in inert gas.

21. The method according to claim 11 , wherein the heating after consolidation is done in air.

22. The method according to claim 3 , wherein the peroxide is selected from the group consisting: diacyl peroxides, peroxyesters, peoxydicarbonates, dialkyl peroxides, ketone peroxides, peroxyketals, cyclic peroxides, peroxymonocarbonates, hydroperoxides, benzoyl peroxide, dicumyl peroxide, methyl ethyl ketone peroxide, acetone peroxide, 2,5-Di(tert-butylperoxy)-2,5-dimethyl-3-hexyne, 3,3,5,7,7-pentamethyl-1,2,4 trioxepane, dilauryl peroxide, methyl ether ketone peroxide, t-amyl peroxyacetate, t-butyl hydroperoxide, t-amyl peroxybenzoate, Di-t-amyl peroxide, 2,5-Dimethyl 2,5-Di(t-butylperoxy)hexane, t-butylperoxy isopropyl carbonate, succinic acid peroxide, cumene hydroperoxide, 2,4-pentanedione peroxide, t-butyl perbenzoate, diethyl ether peroxide, acetone peroxide, arachidonic acid 5-hydroperoxide, carbamide peroxide, tert-butyl hydroperoxide, t-butyl peroctoate, t-butyl cumyl peroxide, Di-sec-butyl-peroxydicarbonate, Di-2-ethylhexylperoxydicarbonate, 1,1-Di(t-butylperoxy)cyclohexane, 1,1-Di(tert-butylperoxy)-3,3,5-trimethylcyclohexane, 2,5-Dimethyl-2,5-di(tert-butylperoxy)hexane, 3,3,5,7,7-Pentamethyl-1,2,4-trioxepane, Butyl 4,4-di(tert-butylperoxy)valerate, Di(2,4-dichlorobenzoyl) peroxide, Di(4-methylbenzoyl) peroxide, Di(tert-butylperoxyisopropyl)benzene, tert-Butyl cumyl peroxide, tert-Butyl peroxy-3,5,5-trimethylhexanoate, tert-Butyl peroxybenzoate, and tert-Butylperoxy 2-ethylhexyl carbonate, or mixtures thereof.

23. The method according to claim 19 , wherein the peroxide is selected from the group consisting: diacyl peroxides, peroxyesters, peoxydicarbonates, dialkyl peroxides, ketone peroxides, peroxyketals, cyclic peroxides, peroxymonocarbonates, hydroperoxides, benzoyl peroxide, dicumyl peroxide, methyl ethyl ketone peroxide, acetone peroxide, 2,5-Di(tert-butylperoxy)-2,5-dimethyl-3-hexyne 3,3,5,7,7-pentamethyl-1,2,4 trioxepane, dilauryl peroxide, methyl ether ketone peroxide, t-amyl peroxyacetate, t-butyl hydroperoxide, t-amyl peroxybenzoate, Di-t-amyl peroxide, 2,5-Dimethyl 2,5

Assignees

• Massachusetts Gen Hospital

Inventors

• Muratoglu Orhun K
• Oral Ebru

Classifications

• B29C35/0866

  using particle radiation · CPC title

• B65B55/08

  by irradiation · CPC title

• C08J7/12

  Chemical modification · CPC title

• B29C43/10

  Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies · CPC title

• B29C2035/085

  using gamma-ray · CPC title