Porous biocompatible polymer material and methods

Patent metadata

Field	Value
Publication number	US-11679181-B2
Application number	US-201916730488-A
Country	US
Kind code	B2
Filing date	Dec 30, 2019
Priority date	Feb 1, 2008
Publication date	Jun 20, 2023
Grant date	Jun 20, 2023

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. An orthopedic implant comprising:
a composite body comprising a plurality of thermoplastic polymers, the composite body including a first porous portion and a second solid portion bonded to the first porous portion;
wherein the first porous portion comprises a first thermoplastic polymer of the plurality of thermoplastic polymers that comprises a PEAK family polymer and the second solid portion comprises a second thermoplastic polymer of the plurality of thermoplastic polymers that comprises polyethylene; and,
wherein the first porous portion comprises a network of granules of the first thermoplastic polymer bonded together a contact points and defining a plurality of interstitial spaces between the network of granules.

2. The orthopedic implant of claim 1 , wherein the second thermoplastic polymer further comprises PAEK family, PCL, PLA, PGA, polyphenylene, polyphenylsulphone, polysulphone, PET, polyurethane, or combinations thereof.

3. The orthopedic implant of claim 1 , wherein the PEAK family polymer is PEEK or carbon reinforced PEEK.

4. The orthopedic implant of claim 1 , wherein the network of granules are melt-bonded together at the contact points.

5. The orthopedic implant of claim 1 , wherein the interstitial spaces have a pore size in the range 5 μm to 5000 μm.

6. The orthopedic implant of claim 1 , wherein the granules have an average size in the range of about 0.25 mm to about 1.0 mm.

7. The orthopedic implant of claim 1 , wherein the first porous portion has an average porosity of between about 30% to about 45%.

8. The orthopedic implant of claim 1 , wherein the first thermoplastic polymer further comprises PAEK family, PCL, PLA, PGA, polyphenylene, polyphenylsulphone, polysulphone, PET, polyethylene, polyurethane, or combinations thereof.

9. The orthopedic implant of claim 8 , wherein the first thermoplastic polymer further comprises PAEK family polymer.

10. The orthopedic implant of claim 9 , wherein the PAEK family polymer is PEEK, carbon reinforced PEEK, PEKK, PEK, or PEKEKK, or combinations thereof.

11. The orthopedic implant of claim 10 , wherein the PAEK family polymer is PEEK or carbon reinforced PEEK.

12. The orthopedic implant of claim 1 , wherein the second solid portion is configured in the shape of a solid core, a solid band, or a solid skin.

13. The orthopedic implant of claim 12 , wherein the second solid portion is configured in the shape of a solid skin.

14. The orthopedic implant of claim 1 , wherein each granule of the network of granules defines a polymer granule surface, and wherein each polymer granule surface defines a microporous surface porosity comprising a plurality of micropores.

15. The orthopedic implant of claim 14 , wherein the microporous surface porosity is in the range of about 0.1 μm to about 100 μm.

16. The orthopedic implant of claim 14 , wherein the polymer granule surface further comprises a coating powder on at least a portion of the polymer granule surface.

17. The orthopedic implant of claim 16 , wherein the coating powder comprises coating powder particles having a size in the range of 0.1 microns to 100 microns.

Assignees

• Depuy Synthes Products Inc

Inventors

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

Classifications

• A61F2002/30062

  (bio)absorbable, biodegradable, bioerodable, (bio)resorbable, resorptive · CPC title

• A61L27/50

  Materials characterised by their function or physical properties {, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials} · CPC title

• A61F2002/30604

  modular · CPC title

• C08J9/26

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

• A61F2310/00976

  Coating or prosthesis-covering structure made of proteins or of polypeptides, e.g. of bone morphogenic proteins BMP or of transforming growth factors TGF · CPC title