Peroxide cross-linking and high temperature melting

Patent metadata

Field	Value
Publication number	US-10981302-B2
Application number	US-201916291283-A
Country	US
Kind code	B2
Filing date	Mar 4, 2019
Priority date	Oct 17, 2013
Publication date	Apr 20, 2021
Grant date	Apr 20, 2021

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 medical implant comprising a cross-linked polymeric material made by 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 medical implant according to claim 1 , wherein at least one antioxidant is vitamin E or Tetrakis[methylene(3,5-di-tertbutylhydroxyhydrocinnamate)] methane.

3. The medical implant 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 medical implant according to claim 1 , wherein the heating after consolidation is done in inert gas.

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

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

7. The medical implant according to claim 1 , wherein the crosslinked polymeric material is further machined into a medical implant.

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

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

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

11. An interlocked hybrid material made by 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 interlocked hybrid material according to claim 11 , wherein the second material is a porous metal.

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

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

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

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

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

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

19. The interlocked hybrid material 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 interlocked hybrid material according to claim 11 , wherein the heating after consolidation is done in inert gas.

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

22. The medical implant 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-butylperoxydicarbonate, Di-2-ethyl hexyperoxydicarbonate, 1,1-Di(t-butylperoxy)cyclohexane, 1, 1-Di(tertbutyl peroxy)-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 interlocked hybrid material 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 pero

Assignees

• Massachusetts Gen Hospital

Inventors

• Muratoglu Orhun K
• Oral Ebru

Classifications

• B65B55/10

  by liquids or gases · CPC title

• B29L2031/7532

  Artificial members, protheses · CPC title

• B29C35/0805 Primary

  using electromagnetic radiation · CPC title

• B29K2995/0087

  Wear resistance · CPC title

• B29K2105/0035

  Medical or pharmaceutical agents · CPC title