Relic process for producing bioresorbable ceramic tissue scaffolds

• US 6,667,049 B2
• Filed: 03/28/2001
• Issued: 12/23/2003
• Est. Priority Date: 06/14/1999
• Status: Expired due to Fees

• Current Assignee: Ethicon Incorporated (Johnson & Johnson)
• Original Assignee: Ethicon Incorporated (Johnson & Johnson)
• Inventors: Janas, Victor F., TenHuisen, Kevor Shane
• Primary Examiner(s): Naff, David M.
• Application Number:
  US09/819,214
• Publication Number:
  US 20010016353A1
• Time in Patent Office: 1,000 Days
• Field of Search: 435/176, 435/180, 435/395, 435/399, 435/283.1, 435/284.1, 424/423, 424/93.7
• US Class Current: 424/423
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• 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 2/30965 Reinforcing the prosthesis by embedding particles or fibres during moulding or dipping
• CPC Class Codes: A61F 2/4455 for the fusion of spinal bodies, e.g. intervertebral fusion of adjacent spinal bodies, e.g. fusion cages intervertebral discs A61F2/442
• CPC Class Codes: A61F 2002/2817 Bone stimulation by chemical reactions or by osteogenic or biological products for enhancing ossification, e.g. by bone morphogenetic or morphogenic proteins [BMP] or by transforming growth factors [TGF]
• CPC Class Codes: A61F 2002/2835 Bone graft implants for filling a bony defect or an endoprosthesis cavity, e.g. by synthetic material or biological material
• CPC Class Codes: A61F 2002/30004 the prosthesis being made from materials having different values of a given property at different locations within the same prosthesis
• CPC Class Codes: A61F 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/30062 (bio)absorbable, biodegradable, bioerodable, (bio)resorbable, resorptive
• CPC Class Codes: A61F 2002/30199 Three-dimensional shapes
• CPC Class Codes: A61F 2002/30677 Means for introducing or releasing pharmaceutical products, e.g. antibiotics, into the body
• CPC Class Codes: A61F 2002/30766 Scaffolds for cartilage ingrowth and regeneration
• CPC Class Codes: A61F 2002/30914 Details of the mesh structure, e.g. disposition of the woven warp and weft wires
• CPC Class Codes: A61F 2002/30968 Sintering
• CPC Class Codes: A61F 2002/4648 Means for culturing bone graft
• CPC Class Codes: A61F 2002/4649 Bone graft or bone dowel harvest sites
• CPC Class Codes: A61F 2210/0004 bioabsorbable
• CPC Class Codes: A61F 2230/0063 Three-dimensional shapes
• CPC Class Codes: A61F 2250/0014 having different values of a given property or geometrical feature, e.g. mechanical property or material property, at different locations within the same prosthesis
• CPC Class Codes: A61F 2250/0023 : differing in porosity
• CPC Class Codes: A61F 2310/00179 : Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00293 : containing a phosphorus-containing compound, e.g. apatite
• CPC Class Codes: A61F 2310/00389 : The prosthesis being coated or covered with a particular material
• CPC Class Codes: A61F 2310/00592 : Coating or prosthesis-covering structure made of ceramics or of ceramic-like compounds
• CPC Class Codes: A61F 2310/0097 : Coating or prosthesis-covering structure made of pharmaceutical products, e.g. antibiotics
• CPC Class Codes: A61F 2310/00976 : 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 Class Codes: A61L 27/12 : Phosphorus-containing materials, e.g. apatite

Abstract

A relic process is used to produce bioresorbable ceramic scaffolds that can be used for in vitro or in vivo growth of human or animal tissue such as bone or cartilage. The process involves impregnating an organic fabric template with metal and phosphate ceramic precursors, heat treating the impregnated fabric to decompose the fabric to form a ceramic green body, and sintering the ceramic green body to form the scaffold which has a form analogous to that of the fabric template. Impregnating the fabric may be by soaking the fabric in a solution or sol containing the ceramic precursors. The fabric may be formed into a laminate prior to heat treating. Sintering results in fibers of the fabric being cross-sintered with one another to form a three-dimensional scaffold structure having controlled pore size and distribution. The scaffold may be treated with a material that promotes bone growth through the scaffold.

Claims

1. A process for making biocompatible, bioresorbable ceramic implant device comprising a resorbable hard tissue scaffold, comprising:

a) impregnating an organic fabric with at least one metal ceramic precursor and at least one phosphate ceramic precursor,

b) heat treating the organic fabric to oxidize the fabric and form a biocompatible, bioresorbable ceramic green body, and

c) sintering the biocompatible, bioresorbable ceramic green body, thereby forming said resorbable hard tissue scaffold.

2. The process of claim 1 wherein the organic fabric is impregnated by soaking the organic fabric in a solution or sol containing the at least one metal ceramic precursor and at least one phosphate ceramic precursor.

3. The process of claim 1 wherein prior to heat treating, the organic fabric is formed into a laminate.

4. The process of claim 1 wherein the fabric is formed by a textile operation selected from the group consisting of weaving, braiding, knitting and combinations thereof.

5. The process of claim 1 wherein the phosphate ceramic precursor is selected from the group consisting of triethyl phosphate, triethylphosphite, alkoxides of phosphorus, phenyl dichlorophosphine, phenyl dichlorophosphate, H₃PO₄, H₃PO₄ hydrates, H₃PO₃, P₂O₅, H₄P₂O₇, and combinations thereof.

6. The process of claim 1 wherein the metal ceramic precursor is selected from the group consisting of calcium nitrates, calcium acetates, calcium nitrites, sugar complexes of calcium, organic salts of calcium, calcium alkoxides and combinations thereof.

7. The process of claim 6 wherein the calcium alkoxide is Ca(OR₃)₂ wherein R₃ is an alkyl group.

8. The process of claim 1 wherein after the resorbable hard tissue scaffold is formed, the resorbable hard tissue scaffold is treated with a material that promotes bone growth through the scaffold.