Orthopedic implants having gradient polymer alloys

• US 10,457,803 B2
• Filed: 12/29/2016
• Issued: 10/29/2019
• Est. Priority Date: 07/07/2008
• Status: Active Grant

• Current Assignee: Hyalex Orthopaedics Incorporated
• Original Assignee: Hyalex Orthopaedics Incorporated
• Inventors: Myung, David, Jaasma, Michael J., Kourtis, Lampros, Roberts, Jeffrey G., Hartdegen, Vernon
• Primary Examiner(s): Pepitone, Michael F
• Application Number:
  US15/394,297
• Publication Number:
  US 20170107370A1
• Time in Patent Office: 1,034 Days
• CPC Class Codes: A61F 2/30 Joints
• CPC Class Codes: A61F 2/30988 Other joints not covered by any of the groups A61F2/32 - A61F2/4425
• CPC Class Codes: A61F 2/3099 for temporo-mandibular [TM, TMJ] joints endoprostheses for mandibular reconstruction A61F2/2803
• CPC Class Codes: A61F 2/32 for the hip
• CPC Class Codes: A61F 2/3804 for elbows
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/3872 Meniscus for implantation between the natural bone surfaces
• CPC Class Codes: A61F 2/3877 Patellae or trochleae
• CPC Class Codes: A61F 2/4081 Glenoid components, e.g. cups
• CPC Class Codes: A61F 2/4202 for ankles
• CPC Class Codes: A61F 2/4225 for feet, e.g. toes
• CPC Class Codes: A61F 2/4241 for hands, e.g. fingers
• CPC Class Codes: A61F 2/4261 for wrists
• CPC Class Codes: A61F 2/442 Intervertebral or spinal discs, e.g. resilient non-disc-shaped intervertebral inflatable pockets A61F2/441; non-disc-shaped intervertebral fusion implants A61F2/4455
• CPC Class Codes: A61F 2002/30998 for acromio-clavicular joints
• CPC Class Codes: A61F 2002/4205 Tibial components
• CPC Class Codes: A61F 2002/4238 for tarso-metatarsal joints, i.e. TMT joints
• CPC Class Codes: A61F 2002/4256 for carpo-metacarpal joints, i.e. CMC joints
• CPC Class Codes: A61F 2310/00011 Metals or alloys
• CPC Class Codes: A61F 2310/00179 Ceramics or ceramic-like structures
• CPC Class Codes: C08F 220/06 : Acrylic acid; Methacrylic acid; Metal salts or ammonium salts thereof
• CPC Class Codes: C08F 220/14 : Methyl esters , e.g. methyl (meth)acrylate
• CPC Class Codes: C08F 236/06 : Butadiene
• CPC Class Codes: C08G 18/44 : Polycarbonates
• CPC Class Codes: C08G 18/4854 : Polyethers containing oxyalkylene groups having four carbon atoms in the alkylene group
• CPC Class Codes: C08G 18/7671 : containing only one alkylene bisphenyl group
• CPC Class Codes: C08G 18/831 : by oxygen-containing compounds inclusive of carbonic acid halogenides, carboxylic acid halogenides and epoxy halides by aldehydes C08G18/84, by peroxides C08G18/86
• CPC Class Codes: C08G 18/837 : by silicon containing compounds
• CPC Class Codes: C08G 2270/00 : Compositions for creating interpenetrating networks
• CPC Class Codes: C08G 77/38 : Polysiloxanes modified by chemical after-treatment C08G77/045 takes precedence
• CPC Class Codes: C08L 2205/04 : containing interpenetrating networks
• CPC Class Codes: C08L 33/02 : Homopolymers or copolymers of acids; Metal or ammonium salts thereof
• CPC Class Codes: C08L 75/04 : Polyurethanes
• CPC Class Codes: C08L 75/06 : from polyesters
• CPC Class Codes: C08L 75/16 : having terminal carbon-to-carbon unsaturated bonds

Abstract

Orthopedic implants having a bone interface member and a water swellable IPN or semi-IPN with a stiffness, hydration, and/or compositional gradient from one side to the other and physically attached to the bone interface member. The invention also includes an orthopedic implant system including an implant that may conform to a bone surface and a joint capsule. The invention also includes orthopedic implants with water swellable IPN or semi-IPNs including a hydrophobic thermoset or thermoplastic polymer first network and an ionic polymer second network, joint capsules, labral components, and bone interface members. The invention also includes a method of inserting an orthopedic implant having a metal portion and a flexible polymer portion into a joint, including inserting the implant in a joint in a first shape and changing the implant from a first shape to a second shape to conform to a shape of a bone.

Claims

1. An orthopedic implant comprising:

a water swellable IPN or semi-IPN member having a bearing surface and an attachment zone, the water swellable IPN or semi-IPN member comprising a hydrophobic thermoset or thermoplastic polymer first network and an ionic polymer second network configured to exhibit a compositional gradient between the bearing surface and the attachment zone, wherein the hydrophobic thermoset or thermoplastic polymer is a phase-separated polymer comprising first domains of hard segments and second domains of soft segments and wherein the attachment zone is configured to attach to bone and comprises the hydrophobic first network and not the ionic polymer second network.

2. The implant of claim 1, wherein the compositional gradient forms a stiffness gradient.

3. The implant of claim 1, wherein the bearing surface comprises a non-porous smooth contact surface.

4. The implant of claim 1, further comprising a metallic or ceramic bone interface member attached to the attachment zone.

5. The implant of claim 1, wherein the first network comprises polyurethane.

6. The implant of claim 1, wherein the attachment zone comprises an adhesive.

7. The implant of claim 1, wherein the ionic polymer second network has a fixed charge.

8. The implant of claim 1, wherein a thickness of the IPN or semi-IPN member is less than 5 mm in a thickest region.

9. The implant of claim 1, further comprising a labral component.

10. The implant of claim 1, wherein the implant has a shape selected from the group consisting of:

a cap, a cup, a plug, a mushroom, a patch and a stem.

11. The implant of claim 1, wherein the implant is adapted to fit an acromioclavicular joint, an ankle joint, a condyle, an elbow joint, a finger joint, a glenoid, a hip joint, an intervertebral disc, an intervertebral facet joint, a labrum, a meniscus, a metacarpal joint, a metatarsal joint, a patella, a tibial plateau, a toe joint, a temporomandibular joint, or a wrist joint.

12. An orthopedic implant comprising:

a water swellable IPN or semi-IPN member comprising a first portion, a second portion, a bearing surface, and an attachment surface;

wherein the first portion includes an ionic polymer second network dispersed within a polyurethane first network, the ionic polymer second network exhibiting compositional gradient within the polyurethane first network that decreases from the bearing surface towards the attachment surf ace; and

wherein the second portion comprises the polyurethane first network and not the ionic polymer second network.

13. The implant of claim 12, wherein the compositional gradient forms a stiffness gradient.

14. The implant of claim 12, wherein the bearing surface comprises a non-porous smooth contact surf ace.

15. The implant of claim 12, further comprising a metallic or ceramic bone interface member attached to the attachment surface.

16. The implant of claim 12, wherein the ionic polymer second network has a fixed charge.

17. The implant of claim 12, wherein the implant has a shape selected from the group consisting of:

a cap, a cup, a plug, a mushroom, a patch and a stem.

18. The implant of claim 12, wherein the implant is adapted to fit an acromioclavicular joint, an ankle joint, a condyle, an elbow joint, a finger joint, a glenoid, a hip joint, an intervertebral disc, an intervertebral facet joint, a labrum, a meniscus, a metacarpal joint, a metatarsal joint, a patella, a tibial plateau, a toe joint, a temporomandibular joint, or a wrist joint.

19. The implant of claim 12, wherein a thickness of the IPN or semi-IPN member is less than 5 mm in a thickest region.

20. The implant of claim 12, wherein the attachment surface comprises an adhesive.