Medical implants made of wear-resistant, high-performance polyimides, process of making same and medical use of same

• US 6,686,437 B2
• Filed: 10/23/2001
• Issued: 02/03/2004
• Est. Priority Date: 10/23/2001
• Status: Active Grant

• Current Assignee: M.M.A. Tech Ltd.
• Original Assignee: M.M.A. Tech Ltd.
• Inventors: Bryant, Robert G., Buchman, Alisa, Mendes, David G., Sibony, Simha, Payne, Raymond G.
• Primary Examiner(s): HAMPTON HIGHTOWER, PATRICIA
• Application Number:
  US09/983,182
• Publication Number:
  US 20030097182A1
• Time in Patent Office: 833 Days
• Field of Search: 528/353, 528/170, 264/241, 264/259, 264/255, 264/250, 128/898, 623/66, 623/18.11, 623/16, 623/20
• US Class Current: 528/170
• CPC Class Codes: A61L 27/18 obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C08L 79/08 Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors

Abstract

A medical implant having at least a portion thereof made of a formable, pyromellitic, dianhydride (PMDA)-free, non-halogenated, aromatic polyimide is disclosed. Further disclosed are a process of manufacturing the implant and a method of implanting the implant in a subject in need thereof.

Claims

1. A medical implant comprising at least a portion made of a formable, pyromellitic, dianhydride (PMDA)-free, non-halogenated, thermosetic aromatic polyimide.

2. The medical implant of claim 1, wherein the entire medical implant is made of said polyimide.

3. The medical implant of claim 1, wherein the medical implant is an orthopedic implant.

4. The medical implant of claim 3, wherein the medical implant is selected from the group consisting of:

a permanent endo-prosthesis and a permanent exo-prosthesis.

5. The medical implant of claim 3, wherein the medical implant is a joint replacement phosthesis.

6. The medical implant of claim 1, further comprising a portion made of at least one other material.

7. The medical implant of claim 6, wherein said at least one other material is selected from the group consisting of polymers, ceramics, metals and materials coated with a wear resistance substance.

8. The medical implant of claim 1, wherein said polyimide has the formula (I):

wherein;

Y and Z are each independently selected from the group consisting of a chemical bond between two adjacent aromatic rings, O, CO and substituted phenyl, where Y and Z can be linked to any free position on the adjacent aromatic ring;

X is selected from the group consisting of substituted allyl, vinyl, acetynyl, phenylethynyl and benzocyclobutenyl; and

n represents an integer equal to or greater than 1.

9. The medical implant of claim 8, wherein n is between 1-100.

10. The medical implant of claim 8, wherein:

X is selected from the group consisting of benzocyclobutenyl, acetynyl and phenylethynyl;

Y and Z are each independently selected from the group consisting of a chemical bond between two adjacent aromatic rings and O;

n represents an integer between 10 and 100; and

X, Y, and Z being linked to the adjacent aromatic rings in the 3, 3′

, 4 and 4′

positions.

11. The medical implant of claim 8, wherein the medical implant is an orthopedic implant.

12. The medical implant of claim 11, wherein the medical implant is selected from the group consisting of a permanent endo-prosthesis and a permanent exo-prosthesis.

13. The medical implant of claim 11, wherein the medical implant is a joint replacement prosthesis.

14. The medical implant of claim 8, further comprising a portion made of at least one other material.

15. The medical implant of claim 14, wherein said at least one other material is selected from the group consisting of polymers, ceramics, metals and materials coated with a wear resistance substance.

16. A process of producing a medical implant having at least a portion made of a formable, pyromellitic, dianhydride (PMDA)-free, non-halogenated, thermosetic, aromatic polyimide, the process comprising:

providing said polyimide in a form selected from the group consisting of;

powder form, granule form, pellet form and plate form; and

said polyimide provided in said form into a net shape, comprising at least a portion or said polyimide.

17. The process of claim 16, wherein the entire medical implant is made of said polyimide.

18. The process of claim 16, wherein forming said polyimide is by compression molding.

19. The process of claim 18, wherein said molding is effected at a temperature ranging from about 25 °

C. to about 500 0°

C.

20. The process of claim 19, wherein said molding is further effected at a pressure ranging from 100 PSI to 20,000 PSI.

21. The process of claim 16, wherein the medical implant is an orthopedic implant.

22. The process of claim 21, wherein the medical implant is selected from the group consisting of a permanent endo-prosthesis and a permanent exo-prosthesis.

23. The process of claim 21, wherein the medical implant is a joint replacement prosthesis.

24. The process of claim 16, wherein said polyimide has the formula (I):

wherein;

Y and Z are each independently selected from the group consisting of a chemical bond between two adjacent aromatic rings, O, CO and substituted phenyl, where Y and Z can be linked to any free position on the adjacent aromatic ring;

X is selected from the group consisting of substituted allyl, vinyl, acetynyl, phenylethynyl and benzocyclobutenyl; and

n represents an integer equal to or greater than 1.

25. The process of claim 24, wherein n ranging from about 1 to about 100.

26. The process of claim 24, wherein:

X is selected from the group consisting of benzocyclobutenyl, acetynyl and phenylethynyl;

Y and Z are each independently selected from the group consisting of a chemical bond between two adjacent aromatic rings and O; and

n represents an integer ranging from about 10 to about 100; and

X, Y, and Z being linked to the adjacent aromatic rings in the 3, 3′

, 4 and 4′

positions.

27. A method of implanting a medical implant in a subject, the method comprising:

providing a medical implant having at least a portion made of formable, pyromellitic, dianhydride (PMDA)-free, non-halogenated, thermosetic, aromatic polyimide; and

implanting the medical implant in the subject.

28. The process of claim 27, wherein the entire medical implant is made of said polyimide.

29. The method of claim 27, wherein the medical implant is an orthopedic implant.

30. The method of claim 29, wherein the medical implant is selected from the group consisting of:

a permanent endo-prosthesis and a permanent exo-prosthesis.

31. The method of claim 29, wherein the medical implant is a joint replacement prosthesis.

32. The method of claim 27, wherein the medical implant comprises a portion made of at least one other material.

33. The method of claim 32, wherein said at least one other material is selected from the group consisting of polymers, ceramics, metals and materials coated with a wear resistance substance.

34. The method of claim 27, wherein said polyimide has the formula (I):

wherein

Y and Z are each independently selected from the group consisting of a chemical bond between two adjacent aromatic rings, O, CO and substituted phenyl, where Y and Z can be linked to any free position on the adjacent aromatic ring;

X is selected from the group consisting of substituted allyl, vinyl, acetynyl, phenylethynyl and benzocyclobutenyl; and

n represents an integer equal to or greater than 1.

35. The method of claim 34, wherein n is ranging from about 1 to about 100.

36. The method of claim 34, wherein:

X is selected from the group consisting of benzocyclobutenyl, acetynyl and phenylethynyl;

Y and Z are each independently selected from the group consisting of a chemical bond between two adjacent aromatic rings and O;

n represents an integer ranging from about 10 to about 100; and

X, Y, and Z being linked to the adjacent aromatic rings in the 3, 3′

, 4 and 4′

positions.

37. The method of claim 34, wherein the medical implant is an orthopedic implant.

38. The method of claim 37, wherein the medical implant is selected from the group consisting of a permanent endo-prosthesis and a permanent exo-prosthesis.

39. The method of claim 37, wherein the medical implant is a joint replacement prosthesis.

40. The method of claim 34, wherein said medical implant comprises a portion made of at least one other material.

41. The method of claim 40, wherein said at least one other material is selected from the group consisting of polymers, ceramics, metals and materials coated with a wear resistance substance.

42. A method of treating a disorder associated with orthopedic malformation and/or disfunction and wherein an implantation of artificial implant is needed, in a subject in need of such treatment, the method comprising implanting in said subject an implant having at least a portion thereof made of a formable, pyromellitic, dianhydride (PMDA)-free, non-halogenated, thermosetic, aromatic polyimide.

43. The process of claim 42, wherein the entire medical implant is made of said polyimide.

44. A method of treating a damaged or degenerative arthroplasty associated with malformation and/or disfunction of a joint, and wherein an implantation of an artificial joint implant is needed, in a subject in need of such treatment, the method comprising implanting in said subject an artificial joint implant made of formable, pyromellitic, dianhydride (PMDA)-free, non-halogenated, thermosetic, aromatic polyimide.

45. The process of claim 44, wherein the entire medical implant is made of said polyimide.

46. The method of claim 44, wherein said joint is selected from the group consisting of a joints lacking a joint cavity and a synovial joint.

47. The method of claim 46, wherein said synovial joint is selected from the group consisting of:

a ball and socket joint, a hinge joint, a pivot joint, an ellipsoidal joint, a saddle joint and a gliding joint.

48. The method of claim 46, wherein said synovial joint is selected from the group consisting of a hip joint, a knee joint, an ankle joint, a shoulder joint, an elbow joint, a wrist joint, a finger joint, a finger metacarpal joint, a toe joint, a toe-metatarsal joint and a carpo-metacarpal joint.

49. A medical implant comprising at least a portion made of a formable, pyromellitic, dianhydride (PMDA)-free, non-halogenated, thermosetic, aromatic polyimide, said medical implant being sterile-packaged.