Implant-based repair of osteochondral defects

• US 10,624,987 B2
• Filed: 09/03/2016
• Issued: 04/21/2020
• Est. Priority Date: 09/03/2015
• Status: Active Grant

• Current Assignee: Texas A&M University System
• Original Assignee: Texas A&M University System
• Inventors: Grunlan, Melissa A., Hahn, Mariah S., Saunders, William B.
• Primary Examiner(s): Arnold, Ernst V
• Application Number:
  US15/757,361
• Publication Number:
  US 20180236128A1
• Time in Patent Office: 1,326 Days
• CPC Class Codes: A61F 2/30756 Cartilage endoprostheses A61F2/3603 takes precedence
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/30075 swellable, e.g. when wetted
• CPC Class Codes: A61F 2002/30224 cylindrical
• CPC Class Codes: A61F 2002/30766 Scaffolds for cartilage ingrowth and regeneration
• CPC Class Codes: A61L 2300/412 Tissue-regenerating or healing or proliferative agents
• CPC Class Codes: A61L 2420/04 Coatings containing a composite material such as inorganic/organic, i.e. material comprising different phases
• CPC Class Codes: A61L 2420/08 Coatings comprising two or more layers
• CPC Class Codes: A61L 2430/02 for reconstruction of bones; weight-bearing implants
• CPC Class Codes: A61L 2430/06 for cartilage reconstruction, e.g. meniscus
• CPC Class Codes: A61L 27/16 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: A61L 27/18 obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: A61L 27/52 Hydrogels or hydrocolloids
• CPC Class Codes: A61L 27/54 Biologically active materials, e.g. therapeutic substances A61L27/227 takes precedence
• CPC Class Codes: A61L 27/56 Porous materials, e.g. foams or sponges
• CPC Class Codes: C08L 71/02 Polyalkylene oxides
• CPC Class Codes: C08L 83/04 Polysiloxanes

Abstract

The present invention is directed to a unique technology for preparing a growth-factor free, cylindrical, hydrogel implant that has multiple (three or more) longitudinal hydrogel zones with varying chemical and physical properties. The implant may be wholly made of hydrogels or the hydrogels may be associated with cells, such as mesenchymal stem cells (MSCs).

Claims

1. A hydrogel implant comprising three or more hydrogel zones, wherein each hydrogel zone exhibits distinct tunable chemical and/or physical properties relative to one another and exhibits interpenetration between the adjacent hydrogel zones, and wherein the hydrogel zones comprise an inorganic polymer and an organic polymer wherein the inorganic polymer is methacrylated star polydimethylsiloxane and the organic polymer is diacrylated poly(ethylene glycol).

2. The hydrogel implant of claim 1, wherein the hydrogel implant is non-porated.

3. The hydrogel implant of claim 2, wherein a first hydrogel zone is fabricated from a first precursor solution comprising about 20:

80 weight % ratio of inorganic polymer to organic polymer.

4. The hydrogel implant of claim 2, wherein a second hydrogel zone is fabricated from a second precursor solution comprising about 10:

90 weight % ratio of inorganic polymer to organic polymer.

5. The hydrogel implant of claim 2, wherein a third hydrogel zone is fabricated from a third precursor solution comprising about 0:

100 weight % ratio of inorganic polymer to organic polymer.

6. The hydrogel implant of claim 1, wherein the hydrogel implant is porated.

7. The hydrogel implant of claim 6, wherein a first hydrogel zone is fabricated from a first precursor solution comprising about 20:

80 weight % ratio of inorganic polymer to organic polymer.

8. The hydrogel implant of claim 6, wherein a second hydrogel zone is fabricated from a second precursor solution comprising about 10:

90 weight % ratio of inorganic polymer to organic polymer.

9. The hydrogel implant of claim 6, wherein a third hydrogel zone is fabricated from a third precursor solution comprising about 0:

100 weight % ratio of inorganic polymer to organic polymer.

10. The hydrogel implant of claim 1, wherein the three or more hydrogel zones are at least one of discrete layers and continuous gradients of different compositions.

11. The hydrogel implant of claim 1, wherein at least one of the three or more hydrogel zones has a different porosity.

12. The hydrogel implant of claim 1, wherein the three or more hydrogel zones are a combination of non-porated and porated zones.

13. A method of preparing a hydrogel implant according to claim 1 comprising:

preparing a first precursor solution comprised of about 20;

80 weight % ratio of inorganic polymer to organic polymer;

placing the first precursor solution layer within a cylindrical glass chamber;

curing the first precursor solution layer to form a first hydrogel zone;

preparing a second precursor solution comprised of a 10;

90 weight % ratio of inorganic polymer to organic polymer 10 weight % in water;

placing the second precursor solution layer within the cylindrical glass chamber over the first hydrogel zone;

curing the second precursor solution layer to form a second hydrogel zone;

preparing a third precursor solution comprised of a 0;

100 weight % ratio of inorganic polymer to organic polymer;

placing the third precursor solution layer within the cylindrical glass chamber over the first hydrogel zone; and

curing the third precursor solution layer to form a third hydrogel zone, wherein the combination of the first hydrogel zone, the second hydrogel zone and the third hydrogel zone forms a hydrogel implant.

14. The method of claim 13, comprising adding additional hydrogel zones to the hydrogel implant by preparing additional precursor solutions, and sequentially placing the additional precursor solutions within the cylindrical glass chamber, over the top hydrogel zone of the hydrogel implant, and curing the additional precursor solution to form the additional hydrogel zone.

15. The method of claim 13, where the hydrogel implant is formed by placing the precursor solutions are cast over a poragen template placed within the cylindrical glass chamber, wherein the poragen template is comprised of salt, NaCI, CaCl₂, RbCl₂, paraffin, or sugar.

16. The method of claim 15, wherein the hydrogel implant is immersed in an aqueous solution to remove the poragen template prior to removing the hydrogel implant from the cylindrical glass chamber.

17. The method of claim 13, where each hydrogel zone is crosslinked to the adjacent hydrogel zone.

18. The method of claim 17, wherein the crosslinking is peformed using a chemical crosslinker.

19. The method of claim 17, wherein the crosslinking is performed using ultraviolet light.

20. A method for treating osteochondral defects in a subject, the method comprising:

shaping the defect to accommodate a hydrogel implant according to claim 1 using arthroscopic techniques, implanting an autograft-sized, hydrogel implant, as determined by the arthroscopic technique used to shape the defect, providing structural support to the defect such that the hydrogel implant acts as support scaffolding and in the regeneration of the tissue types proximate to each hydrogel zone along the longitudinal axis of the hydrogel implant.