Biocompatible material and prosthetic device made thereof for the replacement, repair and regeneration of meniscus

• US 8,901,202 B2
• Filed: 12/14/2005
• Issued: 12/02/2014
• Est. Priority Date: 12/15/2004
• Status: Active Grant

• Current Assignee: Anika Therapeutics Incorporated
• Original Assignee: Anika Therapeutics Incorporated, Luigi Ambrosio
• Inventors: Pastorello, Andrea, Ambrosio, Luigi, Tafuri, Gennaro, Pavesio, Alessandra
• Primary Examiner(s): Heincer, Liam J
• Application Number:
  US11/793,409
• Publication Number:
  US 20080097605A1
• Time in Patent Office: 3,275 Days
• Field of Search: 525/54.3, 523/113, 523/115
• US Class Current: 523/113
• CPC Class Codes: A61F 2/30756 Cartilage endoprostheses A61F2/3603 takes precedence
• CPC Class Codes: A61F 2/30965 Reinforcing the prosthesis by embedding particles or fibres during moulding or dipping
• CPC Class Codes: A61F 2/3872 Meniscus for implantation between the natural bone surfaces
• 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 2002/30062 (bio)absorbable, biodegradable, bioerodable, (bio)resorbable, resorptive
• CPC Class Codes: A61F 2002/30133 kidney-shaped or bean-shaped
• CPC Class Codes: A61F 2002/30957 using a positive or a negative model, e.g. moulds
• CPC Class Codes: A61F 2002/30971 Laminates, i.e. layered products
• CPC Class Codes: A61F 2210/0004 bioabsorbable
• CPC Class Codes: A61F 2230/0015 Kidney-shaped, e.g. bean-shaped
• CPC Class Codes: A61F 2310/00365 Proteins; Polypeptides; Degradation products thereof
• CPC Class Codes: A61L 27/26 Mixtures of macromolecular compounds
• CPC Class Codes: A61L 27/34 Macromolecular materials
• CPC Class Codes: A61L 27/48 with macromolecular fillers
• CPC Class Codes: A61L 27/56 Porous materials, e.g. foams or sponges
• CPC Class Codes: C08L 5/08 Chitin; Chondroitin sulfate; Hyaluronic acid; Derivatives thereof
• CPC Class Codes: C08L 67/04 Polyesters derived from hydroxycarboxylic acids, e.g. lactones C08L67/06 takes precedence

Abstract

Herein described is a biocompatible material comprising a polymer matrix based on hyaluronic acid derivatives and poly-εCaprolactone, the process for preparing this material, a prosthetic device constituted by this biocompatible material and a reinforcing material, the process for preparing the prosthetic device, and its use for the partial or total replacement of meniscus, and regeneration of the meniscal fibrocartilage.

Claims

1. A biocompatible material comprising a polymer matrix having intercommunicating pores and consisting of poly-ε

Caprolactone mixed with a hyaluronic acid derivative, wherein the concentration of poly-ε

Caprolactone ranges between 30 and 70% by weight with respect to the total weight of the polymer matrix, and wherein said hyaluronic acid derivative is benzyl ester of hyaluronic acid having a degree of esterification of from 50 to 100%.

2. The biocompatible material according to claim 1, wherein the concentration of poly-ε

Caprolactone ranges between 50 and 70% by weight with respect to the total weight of said polymer matrix.

3. The biocompatible material according to claim 1, wherein said hyaluronic acid derivative is benzyl ester of hyaluronic acid having a degree of esterification of from 75 to 100%.

4. A process for the preparation of the biocompatible material according to claim 1, said process comprising the following steps:

i) preparing a solution of poly-ε

Caprolactone in a suitable solvent or solvents mixture;

ii) mixing the hyaluronic acid derivative in powder form with a pore-forming agent in an anhydrous environment;

iii) pouring the solution of poly-ε

Caprolactone coming from step i) onto the mixture coming from step ii) and mixing together, thus obtaining the desired polymer matrix.

5. The process according to claim 4, wherein said solution in step i) is a solution of poly-ε

Caprolactone in a solvents mixture consisting of tetrahydrofurane, dimethylsulphoxide and ethanol.

6. The process according to claim 5, wherein said solvents mixture consists of 70.5% v/v tetrahydrofurane, 19.75% v/v dimethylsulphoxide and 9.75% v/v ethanol.

7. The process according to claim 4, wherein step i) is carried out at an initial temperature ranging from 30 to 40°

C.

8. The process according to claim 4, wherein said pore-forming agent is a mixture of citric acid, NaCl and NaHCO₃.

9. The process according to claim 8, wherein said mixture consists of 93.8% w/w of NaCl having granulometry ranging from 315 to 400 μ

m, 3.5% w/w of NaHCO₃ having granulometry ranging from 140 to 400 μ

m and 2.7% of citric acid having granulometry lower than 200 μ

m.

10. The process according to claim 4, wherein the weight ratio of the hyaluronic acid derivative and PCL to the pore-forming agent is 1/10.

11. A prosthetic device comprising a reinforcing material in the form of fibres and/or tissues, and a lyophilisate of the biocompatible material according to claim 1, optionally coated by hyaluronic acid or a derivative thereof.

12. The prosthetic device according to claim 11, wherein said reinforcing material consists of fibres, uniformly distributed and/or arranged circumferentially in said lyophilisate of the biocompatible material.

13. The prosthetic device according to claim 11, wherein said reinforcing material consists of a tissue, placed parallel to the tibial plate and integrated in said lyophilisate of the biocompatible material.

14. The prosthetic device according to claim 11, wherein said reinforcing material consists of two tissues placed on a parallel plane to the tibial plate and integrated in said lyophilisate of the biocompatible material, one of said two tissues being limited to the peripheral portion only.

15. The prosthetic device according to claim 11, wherein said reinforcing material consists of one tissue placed on the edge of the meniscus and one placed on a plane parallel to the tibial plate, both tissues being integrated in said lyophilisate of the biocompatible material.

16. The prosthetic device according to claim 11, wherein said reinforcing material consists of one tissue on the edge of the meniscus connected with a second tissue placed on a parallel plane to the tibial plate, both tissues being integrated in said lyophilisate of the biocompatible material.

17. The prosthetic device according to claim 11, wherein said reinforcing material consists of a bioresorbable polymer and/or a non-bioresorbable polymer.

18. The prosthetic device according to claim 17, wherein said bioresorbable polymer is selected from the group consisting of polylactic acid, polyglycolic acid, collagen and mixtures thereof, and said non-bioresorbable polymer is selected from the group consisting of polypropylene, polyester, polyethylene terephthalate, polytetrafluoroethylene and mixtures thereof.

19. The prosthetic device according to claim 11, wherein said reinforcing material consists of fibres of polylactic acid.

20. The prosthetic device according to claim 11, wherein said reinforcing material consists of tissues of polylactic acid and polyglycolic acid.

21. The prosthetic device according to claim 11, further comprising partially differentiated and/or differentiated mesenchymal cells.

22. The prosthetic device according to claim 11, further comprising hyaline cartilage cells and/or meniscal fibrocartilage cells previously grown in vitro.

23. The prosthetic device according to claim 11, further comprising bone marrow taken and seeded during surgical implant.

24. The prosthetic device according to claim 11, having the shape of the meniscus or a portion thereof.

25. A prosthetic device according to claim 11, for the partial or total replacement of the meniscus, for the repair of damaged menisci, and for the regeneration of the meniscal fibrocartilage.

26. A process for the preparation of the prosthetic device according to claim 11, said process comprising the following steps:

i′

) pouring the biocompatible polymer mixture of PCL and hyaluronic acid derivatives into a meniscus-shaped mould;

ii′

) inserting a reinforcing material in the form of fibres and/or tissues into the polymer mixture;

iii′

) drying the material coming from step ii′

) at room temperature, then removing the solidified material from the mould, dipping it into water and carry out one or more washings;

iv′

) dipping the desiccated and washed material coming from step iii′

) into water at a temperature of 40°

C.;

v′

) removing water from the material coming from step iv′

) by lyophilisation by freeze drying technique;

vi′

) sterilising the freeze-dried material coming from step iv′

).

27. The process according to claim 26, wherein the material coming from freeze-drying in step v′

) is immersed into an aqueous solution of hyaluronic acid or a derivative thereof, and subjected to one or more cycles of depressurisation and release to room pressure;

then water is removed by a second lyophilisation step by freeze drying technique, and the freeze-dried material is finally sterilised as in step vi′

).