Prosthetic devices

• US 9,144,628 B2
• Filed: 08/14/2013
• Issued: 09/29/2015
• Est. Priority Date: 09/11/2007
• Status: Active Grant

• Current Assignee: Solvay Specialty Polymers USA, LLC (Solvac SA)
• Original Assignee: Solvay Specialty Polymers USA, LLC (Solvac SA)
• Inventors: Thomas, David B., Maljkovic, Nikica, El-Hibri, Mohammad Jamal, Schuler, Timothy, Rushing, Todd S., Carter, Roy L.
• Primary Examiner(s): Truong, Duc
• Application Number:
  US13/966,340
• Publication Number:
  US 20140045967A1
• Time in Patent Office: 776 Days
• Field of Search: 525/471, 525/534, 528/220, 523/115, 523/105
• US Class Current: 1/1
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61L 27/18 obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: A61L 27/26 Mixtures of macromolecular compounds
• CPC Class Codes: A61L 27/34 Macromolecular materials
• CPC Class Codes: A61L 27/44 having a macromolecular matrix
• CPC Class Codes: A61L 27/446 with other specific inorganic fillers other than those covered by A61L27/443 or A61L27/46
• CPC Class Codes: C08G 2261/312 Non-condensed aromatic systems, e.g. benzene
• CPC Class Codes: C08L 65/02 Polyphenylenes
• CPC Class Codes: C08L 71/00 Compositions of polyethers obtained by reactions forming an ether link in the main chain of polyacetals C08L59/00; of epoxy resins C08L63/00; of polythioether-ethers C08L81/02; of polyether-sulfones C08L81/06; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 71/12 Polyphenylene oxides
• CPC Class Codes: C08L 81/06 Polysulfones; Polyethersulfones

Abstract

A prosthetic device made of a first specific type of polyarylene, taken alone or in combination with a second specific type of polyarylene, featuring some unexpected advantages such as a very high strength and stiffness, good elongation properties, high chemical resistance, good biocompatibility as well as an outstanding impact resistance.

Claims

1. A prosthetic device comprising at least one part consisting of a material consisting of:

at least one polyarylene (P2) comprising efficient arylene recurring units (R2), wherein the efficient arylene recurring units (R2) are a mix (M2) consisting of;

less than 70 mole %, down to 0 mole %, based on the total number of moles of efficient arylene recurring units (R2), of rigid rod-forming arylene units (Ra), said rigid rod-forming arylene units (Ra) being optionally substituted by at least one monovalent substituting group

with

more than 30 mole %, up to 100 mole %, based on the total number of moles of efficient arylene recurring units (R2), of kink-forming arylene units (Rb), said kink-forming arylene units being optionally substituted by at least one monovalent substituting group,

and

optionally at least one additive selected from the group consisting of fibrous reinforcing agents, char promoters, particulate fillers, nucleating agents, adhesion promoters, compatibilizers, curing agents, lubricants, metal particles, mold release agents, organic and/or inorganic pigments, dyes, flame retardants, smoke-suppressing agents, heat stabilizers, antioxidants, UV absorbers, tougheners, plasticizers, anti-static agents, and melt viscosity depressants,

wherein the prosthetic device is an orthopaedic prosthesis, a dental structure, an artificial body part selected from the group consisting of limbs, eyes, and implants, or a fixed prosthetic anatomical device.

2. A prosthetic device as claimed in claim 1, wherein said prosthetic device is:

an orthopaedic prosthesis comprising a manufactured replacement for an end and/or an articulating surface of a bone;

a manufactured replacement for a portion of a bone distant from an articulating surface;

or

an artificial body part selected from the group consisting of limbs, eyes, and implants.

3. A prosthetic device as claimed in claim 1, wherein said prosthetic device is an orthopaedic prosthesis.

4. The prosthetic device according to claim 1, wherein essentially all the recurring units of the polyarylene (P2) are said efficient arylene recurring units (R2).

5. The prosthetic device according to claim 1, wherein all the recurring units of the polyarylene (P2) are said efficient arylene recurring units (R2).

6. The prosthetic device according to claim 1, wherein all the recurring units of the polyarylene (P2) are said efficient arylene recurring units (R2) and said mix (M2) consists of p-phenylene units substituted by a phenylketone group with unsubstituted m-phenylene units, in a mole ratio of about 50:

50.

7. The prosthetic device according to claim 1, wherein all the recurring units of the polyarylene (P2) are said efficient arylene recurring units (R2) and said mix (M2) consists of p-phenylene units substituted by a phenylketone group with unsubstituted m-phenylene units, in a mole ratio of about 25:

75 to 65;

35.

8. The prosthetic device according to claim 1, wherein all the recurring units of the polyarylene (P2) are said efficient arylene recurring units (R2) and said mix (M2) consists of p-phenylene units substituted by a phenylketone group with unsubstituted m-phenylene units, in a mole ratio of about 35:

65 to 60;

40.

9. The prosthetic device according to claim 1, wherein all the recurring units of the polyarylene (P2) are said efficient arylene recurring units (R2) and said mix (M2) consists of p-phenylene units substituted by a phenylketone group with unsubstituted m-phenylene units, in a mole ratio of about 45:

55 to 55;

45.

10. The prosthetic device according to claim 1, wherein said mix (M2) consists of p-phenylene units substituted by a phenylketone group with unsubstituted m-phenylene units, in a mole ratio of about 50:

50.

11. The prosthetic device according to claim 1, wherein said polyarylene (P2) comprises less than 10 ppm of Ni, less than 200 ppm of Zn, and less than 1000 ppm of P.

12. The prosthetic device according to claim 1, wherein said polyarylene (P2) comprises less than 5 ppm Ni, less than 50 ppm Zn, and less than 800 ppm P.

13. The prosthetic device according to claim 1, wherein said material consists of said at least one polyarylene (P2).

14. The prosthetic device according to claim 1, wherein said material consists of said at least one polyarylene (P2) and said at least one additive.

15. The prosthetic device according to claim 14, wherein said material comprises a char promoter.

16. The prosthetic device according to claim 15, wherein said char promoter is a phenoxy derivative.

17. The prosthetic device according to claim 15, wherein said char promoter is an inorganic oxide, a salt, or a combination thereof.

18. The prosthetic device according to claim 17, wherein said char promoter is a combination of one or more oxides and one or more salts.

19. The prosthetic device according to claim 15, wherein said char promoter is CuCr₂O₄.MnO.

20. The prosthetic device according to claim 15, wherein the material comprises between 0.01 and 10 wt. % of the char promoter, based on the total weight of the material.