Polymer re-inforced anatomically accurate bioactive protheses
First Claim
1. A method for forming an implant having an inner core and an outer layer which comprises:
- fabricating a preform with an open pore network;
coating at least a portion of the outer layer of the preform with a fugitive material to form an inhibition layer and to define infusion channels;
infusing selected regions of the inner core through the infusion channels with at least one infusing media;
forming an interpenetrating phase composite in the inner core; and
removing the fugitive material from the outer layer thereby forming a porous outer layer.
1 Assignment
0 Petitions
Accused Products
Abstract
Customized implants for use in reconstructive bone surgeries where anatomical accuracy and bone adaptation are important, such as plastic and craniomaxillofacial reconstructions. This implant comprises a porous surface layer and a tough inner core of interpenetrating phase composite. The porous surface layer enhances the biocompatibility, tissue ingrowth, and implant stability. The tough inner core improves the mechanical properties of the implant with a high fracture toughness and a low modulus. The anatomical accuracy of the implants will minimize the intra-operative manipulation required to maintain a stable host bone-implant interface.
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Citations
29 Claims
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1. A method for forming an implant having an inner core and an outer layer which comprises:
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fabricating a preform with an open pore network;
coating at least a portion of the outer layer of the preform with a fugitive material to form an inhibition layer and to define infusion channels;
infusing selected regions of the inner core through the infusion channels with at least one infusing media;
forming an interpenetrating phase composite in the inner core; and
removing the fugitive material from the outer layer thereby forming a porous outer layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 27)
infusing the inner core with at least two infusion media.
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7. The method of claim 5 which comprises:
infusing the inner core with an inorganic material selected from the group consisting of resorbable glasses and silica.
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8. The method of claim 5 which comprises:
infusing the inner core with a material selected from the group consisting of drug molecules, growth factors, adhesion peptides, promotors and activators.
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9. The method of claim 5 which comprises:
infusing the inner core with inorganic precursors selected from the group consisting of alkoxides, metal alkoxides, silicon alkoxides, non-silicate tetravalent metal alkoxides and sol-gel organic-inorganic hybrids.
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10. The method of claim 5 which comprises:
removing fugitive material.
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27. The method of claim 5 wherein the acrylates are selected from the group consisting of TEGDMA (triethylene glycol dimethacrylate), MMA (methyl methacrylate), and Bis GMA (2,2-bis[4(2-hydroxy-3 methacryloyloxy-propyloxy)-phenyl] propane);
- the thermophalstics are selected from the group consisting of styrene, vinyl acetate, vinyl choloride, polyethylene, PTFE (potytetraflouroethylene) and polypropylene;
the epoxies are selected from the group consisting of polytherketone, polyetheretherketone, and polyphenylene oxide;
the resorbable polymers are selected from the group consisting of polylactic acid, polyglycolic acid, polycaprolactone, polytrimethylene carbonate, polydioxanone, polyiminocarbonates, polyamides, polyorthoesters, polyanhydrides, polyhydroxyalkanoates, and polyhydroxybutyrate; and
the water soluble/hydrophilics are selected from the group consisting of polyvinyl alcohol, polyvinyl alcohol-based mixtures, collagen gel/poly alpha hydroxyacids, cellulose and waxes.
- the thermophalstics are selected from the group consisting of styrene, vinyl acetate, vinyl choloride, polyethylene, PTFE (potytetraflouroethylene) and polypropylene;
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11. An implant which comprises:
a preform with an open pore network, the preform having an inner core and an outer layer, the inner core infused with at least two infusion media which form an interpenetrating phase composite in the inner core, the preform characterized by a flexural strength, a modulus and a fracture toughness which matches that of a target bone host, and at least a portion of the outer layer being porous. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 28)
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19. A method for forming an implant having an inner core and an outer layer which comprises:
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fabricating a preform with an open pore network;
coating at least a portion of the outer layer of the preform with a fugitive material to form an inhibition layer and to define infusion channels;
infusing selected regions of the inner core through the infusion channels with at least two infusing media;
forming two interpenetrating phase composites in the inner core; and
removing the fugitive material from the outer layer thereby forming a porous outer layer. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26, 29)
infusing the inner core with an inorganic material selected from the group consisting of resorbable glasses and silica.
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25. The method of claim 23 which comprises:
infusing the inner core with a material selected from the group consisting of drug molecules, growth factors, adhesion peptides, promotors and activators.
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26. The method of claim 23 which comprises:
infusing the inner core with inorganic precursors selected from the group consisting of alkoxides, metal alkoxides, silicon alkoxides, non-silicate tetravalent metal alkoxides and sol-gel organic-inorganic hybrids.
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29. The method of claim 21 wherein the acrylates are selected from the group consisting of TEGDMA (triethylene glycol dimethacrylate), MMA (methyl methacrylate), and Bis GMA (2,2-bis[4(2-hydroxy-3 methacryloyloxy-propyloxy)-phenyl] propane);
- the thermophalstics are selected from the group consisting of styrene, vinyl acetate, vinyl choloride, polyethylene, PTFE (potytetraflouroethylene) and polypropylene;
the epoxies are selected from the group consisting of polytherketone, polyetheretherketone, and polyphenylene oxide;
the resorbable polymers are selected from the group consisting of polylactic acid, polyglycolic acid, polycaprolactone, polytrimethylene carbonate, polydioxanone, polyiminocarbonates, polyamides, polyorthoesters, polyanhydrides, polyhydroxyalkanoates, and polyhydroxybutyrate; and
the water soluble/hydrophilics are selected from the group consisting of polyvinyl alcohol, polyvinyl alcohol-based mixtures, collagen gel/poly alpha hydroxyacids, cellulose and waxes.
- the thermophalstics are selected from the group consisting of styrene, vinyl acetate, vinyl choloride, polyethylene, PTFE (potytetraflouroethylene) and polypropylene;
Specification