Porous biocompatible polymer material and methods

Patent metadata

Field	Value
Publication number	US-10549014-B2
Application number	US-201615066195-A
Country	US
Kind code	B2
Filing date	Mar 10, 2016
Priority date	Feb 1, 2008
Publication date	Feb 4, 2020
Grant date	Feb 4, 2020

Abstract

Embodiments described include devices and methods for forming a porous polymer material. Devices disclosed and formed using the methods described a spacer for spinal fusion, craniomaxillofacial (CMF) structures, and other structures for tissue implants.

First claim

What is claimed is:

1. A porous structure for promoting tissue ingrowth, comprising:
a first solid portion bonded to a second porous portion, wherein the second porous portion comprises
a network of polymer granules-bonded together at contact points; the network of polymer granules defining a plurality of interstitial spaces between the polymer granules,
wherein each polymer granule of the network defines a polymer granule surface, and wherein each polymer granule surface defines a microporous surface porosity comprising a plurality of micropores on the polymer granule surface having a size range of about 0.1 microns to about 100 microns.

2. The porous structure of claim 1 , wherein the structure is a spacer for spinal fusion.

3. The porous structure of claim 1 , wherein the structure is a craniomaxillofacial (CMF) structure.

4. The porous structure of claim 1 , wherein the structure is a scaffold structure.

5. The porous structure of claim 1 , wherein the polymer granules comprise PCL, PLA, PGA, or a mixture thereof.

6. The porous structure of claim 1 , wherein the polymer granules comprise polyphenylene, self-reinforced polyphenylene, polyphenylsulphone, polysulphone, PET, polyethylene, polyurethane, or a mixture thereof.

7. The porous structure of claim 1 , further including a synthetic small molecule.

8. The porous structure of claim 1 , further including a hydrolytically degradable coating.

9. The porous structure of claim 1 , further including one or more radiopaque materials.

10. The porous structure of claim 1 , wherein the second porous portion includes one or more areas of selective compression.

11. The porous structure of claim 1 , wherein the interstitial spaces have a mean pore size of 5 μm to 5000 μm.

12. The porous structure of claim 1 , wherein the interstitial spaces have a mean pore size of 100 μm to 500 μm.

13. The porous structure of claim 1 , wherein the first solid portion comprises PAEK family polymers.

14. The porous structure of claim 1 , wherein the first solid portion comprises PEEK.

15. The porous structure of claim 1 , wherein the first solid portion comprises the same polymer as the second porous portion.

16. The porous structure of claim 1 , wherein the second porous portion has an average porosity of between about 30% to about 45%.

17. The porous structure of claim 1 , wherein the granules have an average size in the range of about 0.25 mm to about 1.0 mm.

18. The porous structure of claim 1 , wherein the second porous portion has a compressive strength in the range of 20 MPa to about 35 MPa.

19. The porous structure of claim 1 , wherein the second porous portion has a compressive strength in the range of 20 MPa to about 45 MPa.

20. The porous structure of claim 1 , wherein the polymer granules comprise PAEK family polymers.

21. The porous structure of claim 20 , wherein the first solid portion comprises PAEK family polymers.

22. The porous structure of claim 1 , wherein the polymer granules comprise PEEK.

23. The porous structure of claim 22 , wherein the first solid portion comprises PEEK.

24. The porous structure of claim 1 , further including a reinforcing structure.

25. The porous structure of claim 24 , wherein the reinforcing structure is incorporated through the porous structure.

26. The porous structure of claim 1 , further including a biological sub stance.

27. The porous structure of claim 26 , wherein the biological substance is autologous.

28. The porous structure of claim 26 , wherein the biological substance is allogenic.

29. The porous structure of claim 26 , wherein the biologically active substance is disposed within the interstitial spaces.

30. The porous structure of claim 26 , further comprising a coating of material configured to control the release of the biologically active substance.

Assignees

• Depuy Synthes Products Inc

Inventors

• Kerr Sean Hamilton
• Recber Ali
• Pepe Thomas
• Messerli Dominique
• Laurence Lawton
• Walsh Ryan
• Kueenzi Thomas
• Randall Brandon

Classifications

• A61P19/08

  for bone diseases, e.g. rachitism, Paget's disease · CPC title

• C08J9/26

  by elimination of a solid phase from a macromolecular composition or article, e.g. leaching out · CPC title

• A61F2002/3097

  using laser · CPC title

• A61F2002/30387

  Dovetail connection · CPC title

• A61F2002/30578

  having apertures, e.g. for receiving fixation screws · CPC title