Modular tissue scaffolds

• US 9,943,410 B2
• Filed: 02/28/2012
• Issued: 04/17/2018
• Est. Priority Date: 02/28/2011
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Inventors: Hollister, Scott J., Feinberg, Stephen E., Murphy, William L., Jongpaiboonkit, Leenaporn, Adox, James R., Migneco, Francesco
• Primary Examiner(s): SUMMITT, LYNNSY M
• Application Number:
  US13/407,441
• Publication Number:
  US 20120271418A1
• Time in Patent Office: 2,240 Days
• Field of Search: 606902, 606903, 606904, 606906, 623 1611, 623 1717, 623 2351, 623 2352
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/2803 for mandibular reconstruction temporo-mandibular joints A61F2/3099; bone plates for the jaw A61B17/8071
• CPC Class Codes: A61F 2/2875 Skull or cranium A61F2/2803 and A61F2/3099 take precedence
• CPC Class Codes: A61F 2002/30062 (bio)absorbable, biodegradable, bioerodable, (bio)resorbable, resorptive
• CPC Class Codes: A61F 2002/30331 made by longitudinally pushing a protrusion into a complementarily-shaped recess, e.g. held by friction fit
• CPC Class Codes: A61F 2002/30387 Dovetail connection
• CPC Class Codes: A61F 2002/30451 soldered or brazed or welded
• CPC Class Codes: A61F 2002/305 Snap connection
• CPC Class Codes: A61F 2002/30604 modular
• CPC Class Codes: A61F 2002/30677 Means for introducing or releasing pharmaceutical products, e.g. antibiotics, into the body
• CPC Class Codes: A61F 2002/30948 using computerized tomography, i.e. CT scans
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/30962 using stereolithography
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

Provided are biocompatible and implantable scaffolds for treating a tissue defect, such as a bone gap. The scaffolds can have a modular design comprising a tissue scaffold rack designed to accommodate one or more modules. Also provided are methods for fabrication and use of such scaffolds.

Claims

1. A biocompatible system for filling a tissue gap comprising:

a first module that is biocompatible and degradable and a second module that is biocompatible and degradable;

wherein one of each module has an irregular disk shape having two flat sides and each module comprises a dovetail connector on each flat side, wherein the dovetail connectors from one of the first or second module is designed to couple with one of the dovetail connectors from the other of the first or second module and wherein the circumference of the irregular disk correspond to a shape of the gap being filled by the tissue scaffold;

a biocompatible and degradable tissue scaffold rack comprising a trough shaped portion having two side regions, a bottom region, a proximal end and a distal end,

wherein the tissue scaffold rack comprises a first coupling portion having a first shape and the first module comprises a second coupling portion having a second shape that corresponds to the first shape, wherein the second coupling portion of the first module is designed to engage with the first coupling portion of the tissue scaffold rack;

wherein the modules fit into the trough shaped region by contacting the bottom region and substantially spanning the two side regions; and

,

each of the first and second module and the rack have a porous microstructure, are synthesized from polycaprolactone and are substantially coated with calcium-deficient carbonate-containing hydroxyapatite.

2. The biocompatible system of claim 1, comprising

a bioactive agent;

and

wherein the system comprises one or more features selected from the group consisting of;

the first module comprises the bioactive agent

the bioactive agent is present in an amount effective to induce ossification;

the bioactive agent is selected from the group consisting of a bone morphogenetic protein (BMP), demineralized bone matrix, a bone marrow aspirate, a transforming growth factor, a fibroblast growth factor, an insulin-like growth factor, a platelet derived growth factor, a vascular endothelial growth factor, a growth and development factor-5, platelet rich plasma, and a mixture thereof;

the bioactive agent is BMP2 or BMP7; and

the first module and the second module a first bioactive agent and a second bioactive agent, respectively, and the first bioactive agent is different than the second bioactive agent.

3. The biocompatible system of claim 1, further comprising

an isolated vertebrate cell;

wherein the system comprises one or more features selected from the group consisting of;

the isolated vertebrate cell is a mammalian cell;

the isolated vertebrate cell is comprised of the first module;

the isolated vertebrate cell is a stem cell;

the isolated vertebrate cell is an embryonic stem cell;

the isolated vertebrate cell is an adult stem cell;

the isolated vertebrate cell is a mesenchymal stem cell;

the isolated vertebrate cell is an induced pluripotent stem cell; and

the first module and the second module comprise a first isolated vertebrate cell and a second isolated vertebrate cell, respectively, and the first isolated vertebrate cell is different than the second isolated vertebrate cell.

4. The biocompatible system of claim 1 wherein

each tissue scaffold module or the rack further comprises a ridge designed to be coupled to at least another module or the rack.

5. The biocompatible system of claim 4, wherein the ridge is configured to be melted by the application of energy, and wherein the application of energy to the ridge fuses the first module or the second module to the rack, or the first module to the second module.

6. The biocompatible system of claim 1, comprising at least one pin for coupling the tissue scaffold to tissue;

and at least one feature selected from the group consisting of;

(i) the tissue is bone;

(ii) the at least one pin is made from a biodegradable and absorbable material;

(iii) the at least one pin is for coupling to the tissue scaffold and adjacent tissue;

(iv) the at least one pin is for coupling to the tissue scaffold and adjacent tissue and the coupling is accomplished by at least one of sonically welding and applying energy to bond the at least one pin to the tissue scaffold and the adjacent tissue;

(v) the pin is synthesized from a material independently selected from a degradable polymer and a mixture of a degradable polymer and a bioceramic;

(vi) the pin is synthesized from a material independently selected from a degradable polymer and a mixture of a degradable polymer and a bioceramic, and the polymer is polycaprolactone, polylactide, polyglycolide, poly(lactide-glycolide), poly(propylene fumarate), poly(caprolactone fumarate), polyethylene glycol, poly(glycolide-co-caprolactone), or mixtures thereof;

(vii) the pin is synthesized from a material independently selected from a degradable polymer and a mixture of a degradable polymer and a bioceramic, and the polymer is polycaprolactone;

(viii) the pin comprises an osteoconductive mineral coating on at least a portion of the pin;

(ix) the pin comprises an osteoconductive mineral coating on at least a portion of the pin and the osteoconductive mineral coating is hydroxyapatite, calciumdeficient carbonate-containing hydroxyapatite, tricalcium phosphate, amorphous calcium phosphate, octacalcium phosphate, dicalcium phosphate, calcium phosphate, or a mixture thereof;

(x) the pin comprises an osteoconductive mineral coating on at least a portion of the pin and the osteoconductive mineral coating is calcium-deficient carbonate-containing hydroxyapatite;

(xi) the pin comprises a bioactive agent;

(xii) the pin comprises a bioactive agent present in an amount that induces ossification;

(xiii) the pin comprises a bioactive agent and the bioactive agent is a bone morphogenetic protein (BMP), demineralized bone matrix, a bone marrow aspirate, a transforming growth factor, a fibroblast growth factor, an insulin-like growth factor, a platelet derived growth factor, a vascular endothelial growth factor, a growth and development factor-5, platelet rich plasma, or a mixture thereof; and

(xiv) the pin comprises a bioactive agent and the bioactive agent is BMP2 or BMP7.

7. The biocompatible system of claim 1, wherein the first module and the second module are designed to protrude through a marrow space to provide fixation when implanted.

8. The biocompatible system of claim 7, further comprising a pin corresponding to each of the first module and the second module to provide additional fixation when implanted.

9. The biocompatible system of claim 1, wherein the second coupling portion of the first module is designed to couple to the first coupling portion of the tissue scaffold rack via a mechanical connection.

10. The biocompatible system of claim 1, wherein the first coupling portion is disposed at the bottom region of the tissue scaffold rack.

11. The biocompatible system of claim 1, wherein the first coupling portion is a recess and the second coupling portion is a protuberance that is configured to fit into the recess.

12. The biocompatible system of claim 1, wherein the second coupling portion is a recess and the first coupling portion is a protuberance that is configured to fit into the recess.

13. The biocompatible system of claim 1, wherein the system comprises a third module that is biocompatible and degradable, wherein the third module comprises both an A connector and a B connector and is joined to the first module or the second module by the third module A connector or B connector.