Continuous phase composite for musculoskeletal repair

• US 8,679,191 B2
• Filed: 01/31/2011
• Issued: 03/25/2014
• Est. Priority Date: 12/08/2004
• Status: Expired due to Fees

• Current Assignee: Zimmer Biomet Spine, Inc. (Zimvie Incorporated)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Borden, Mark D., Hernandez, Joseph M., Shors, Edwin C.
• Primary Examiner(s): Ramana, Anu
• Application Number:
  US13/017,992
• Publication Number:
  US 20110190903A1
• Time in Patent Office: 1,149 Days
• Field of Search: 623 2356- 2363, 623 1711- 1716, 606/70, 606/280, 606/281, 606/283, 606/284
• US Class Current: 623/23.76
• CPC Class Codes: A61B 17/68 Internal fixation devices , including fasteners and spinal fixators, even if a part thereof projects from the skin bone staples A61B17/0642
• CPC Class Codes: A61B 17/864 hollow, e.g. with socket or cannulated
• CPC Class Codes: A61B 17/866 Material or manufacture
• CPC Class Codes: A61B 2017/00004 (bio)absorbable, (bio)resorbable, resorptive for implantable prostheses A61F2210/0004
• CPC Class Codes: A61F 2/4202 for ankles
• 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 2/4465 having a circular or kidney shaped cross-section substantially perpendicular to the axis of the spine
• CPC Class Codes: A61F 2/447 substantially parallelepipedal, e.g. having a rectangular or trapezoidal cross-section
• CPC Class Codes: A61F 2/4611 of spinal prostheses
• CPC Class Codes: A61F 2002/30032 differing in absorbability or resorbability, i.e. in absorption or resorption time
• CPC Class Codes: A61F 2002/30062 (bio)absorbable, biodegradable, bioerodable, (bio)resorbable, resorptive
• CPC Class Codes: A61F 2002/30133 kidney-shaped or bean-shaped
• CPC Class Codes: A61F 2002/30156 triangular
• CPC Class Codes: A61F 2002/302 toroidal, e.g. rings
• CPC Class Codes: A61F 2002/30593 hollow
• CPC Class Codes: A61F 2002/30785 parallel
• CPC Class Codes: A61F 2002/3082 Grooves
• CPC Class Codes: A61F 2002/30904 serrated profile, i.e. saw-toothed
• CPC Class Codes: A61F 2210/0004 bioabsorbable
• CPC Class Codes: A61F 2230/0015 Kidney-shaped, e.g. bean-shaped
• CPC Class Codes: A61F 2230/0023 : triangular
• CPC Class Codes: A61F 2230/0065 : toroidal, e.g. ring-shaped, doughnut-shaped
• CPC Class Codes: A61F 2250/003 : differing in adsorbability or resorbability, i.e. in adsorption or resorption time
• CPC Class Codes: A61F 2310/00179 : Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00796 : Coating or prosthesis-covering structure made of a phosphorus-containing compound, e.g. hydroxy(l)apatite
• CPC Class Codes: A61L 27/446 : with other specific inorganic fillers other than those covered by A61L27/443 or A61L27/46
• CPC Class Codes: A61L 27/46 : with phosphorus-containing inorganic fillers
• CPC Class Codes: A61L 27/56 : Porous materials, e.g. foams or sponges
• CPC Class Codes: A61L 27/58 : Materials at least partially resorbable by the body
• CPC Class Codes: A61L 31/127 : containing fillers of phosphorus-containing inorganic materials
• CPC Class Codes: A61L 31/128 : containing other specific inorganic fillers not covered by A61L31/126 or A61L31/127
• CPC Class Codes: A61L 31/146 : Porous materials, e.g. foams or sponges
• CPC Class Codes: A61L 31/148 : Materials at least partially resorbable by the body

Abstract

A composite material for positioning in the anatomy to form a selected function therein. The composite may be resorbable over a selected period of time. The composite may allow for selected bone ingrowth as absorption of the composite occurs.

Claims

1. A resorbable implant, comprising a member including a composite formed of:

a first material comprising a first resorbable material operable to be resorbed into an anatomy, the first material forming a scaffold having a plurality of pores and a plurality of continuous channels defined at least in part by a first sub-plurality of the plurality of pores, the plurality of channels extending through the scaffold; and

a second material that is a resorbable polymer injected into the scaffold to substantially fill at least a sub-plurality of the plurality of continuous channels so that the polymer forms a continuous structure;

wherein the second material is a polymer selected from the group comprising polylactic acids, polyglycolic acids, and combinations thereof, and forms about 55 wt % to about 65 wt % of the member;

wherein the resorbable polymer is resorbed at a rate slower than a rate of resorption of the scaffold such that the resorbable polymer defines a support for bony ingrowth to maintain a selected strength of the member for a predetermined time period.

2. The implant of claim 1, wherein the second material is operable to resorb at a rate wherein the member remains substantially intact under at least about 2000 Newtons of compressive force for the predetermined time period ending six months after implantation.

3. The implant of claim 1, wherein the member comprises a first wall having a height, a second wall having a height less than the height of the first wall, and a surface extending substantially orthogonal to and between the first wall and the second wall.

4. The implant of claim 3, wherein the member defines a void in the surface.

5. The implant of claim 3, wherein at least one continuous channel extends from the first wall to the second wall of the member.

6. The implant of claim 1, further comprising:

a second sub-plurality of the plurality of continuous channels pores that are only partially filled;

wherein both the first sub-plurality of continuous channels and the second sub-plurality of continuous channels includes pores with interconnecting channels.

7. The implant of claim 1, wherein the implant has a substantially linear rate of strength decrease over time;

wherein rate of strength decrease of the implant is selected based upon the selected second material.

8. The implant of claim 1, wherein the first material comprises an absorbable ceramic.

9. A resorbable implant, comprising a member including a composite formed of:

a scaffold of a first material having a plurality of pores in a surface of the scaffold and a plurality of continuous channels interconnecting at least a first sub-plurality of the plurality of pores, wherein the plurality of continuous channels extend through the scaffold between at least two pores of the plurality of pores; and

a resorbable polymer to substantially fill at least a sub-plurality of the plurality of continuous channels so that the polymer forms a continuous structure within the scaffold;

wherein the resorbable polymer is resorbed at a rate slower than a rate of resorption of the scaffold such that the resorbable polymer defines a support for bony ingrowth to maintain a selected strength of the member.

10. The implant of claim 9, wherein the resorbable polymer is selected from a group comprising polylactic acids, polyglycolic acids, and combinations thereof, and forms about 55 wt % to about 65 wt % of the member.

11. The implant of claim 9, wherein the resorbable polymer is operable to resorb at a rate wherein the member remains substantially intact under at least about 2000 Newtons of compressive force after at least six months after implantation.

12. The implant of claim 9, wherein at least one of the plurality of continuous channels extend from a first wall to a second wall of the member.

13. The implant of claim 12, wherein the implant has a substantially linear rate of strength decrease over time;

wherein rate of strength decrease of the implant is selected based upon the selected second material.

14. The implant of claim 9, wherein the member defines a void in the surface.

15. The implant of claim 9, further comprising:

a second sub-plurality of the plurality of continuous channels are only partially filled;

wherein both the first sub-plurality of continuous channels and the second sub-plurality of continuous channels includes pores at the surface with interconnecting channels between the pores.

16. The implant of claim 9, wherein the first material comprises an absorbable ceramic.