U.S. patent application number 09/193973 was filed with the patent office on 2001-06-21 for mold apparatus and kit for in situ tissue repair.
Invention is credited to ARSENYEV, ALEXANDER, FELT, JEFFREY C., RYDELL, MARK A., ZDRAHALA, RICHARD J..
Application Number | 20010004710 09/193973 |
Document ID | / |
Family ID | 27369064 |
Filed Date | 2001-06-21 |
United States Patent
Application |
20010004710 |
Kind Code |
A1 |
FELT, JEFFREY C. ; et
al. |
June 21, 2001 |
MOLD APPARATUS AND KIT FOR IN SITU TISSUE REPAIR
Abstract
A method, and related composition and apparatus for repairing a
tissue site. The method involves the use of a curable polyurethane
biomaterial composition having a plurality of parts adapted to be
mixed at the time of use in order to provide a flowable composition
and to initiate cure. The flowable composition can be delivered
using minimally invasive means to a tissue site and there fully
cured provide a permanent and biocompatible prosthesis for repair
of the tissue site. Further provided are a mold apparatus, e.g., in
the form of a balloon or tubular cavity, for receiving a
biomaterial composition, and a method for delivering and filling
the mold apparatus with a curable composition in situ to provide a
prosthesis for tissue repair.
Inventors: |
FELT, JEFFREY C.;
(GREENWOOD, MN) ; RYDELL, MARK A.; (GOLDEN VALLEY,
MN) ; ZDRAHALA, RICHARD J.; (EDEN PRAIRIE, MN)
; ARSENYEV, ALEXANDER; (EAGAN, MN) |
Correspondence
Address: |
PHILIP M GOLDMAN
FREDRIKSON AND BYRON
1100 INTERNATIONAL CENTRE
900 2ND AVE S
MINNEAPOLIS
MN
554023397
|
Family ID: |
27369064 |
Appl. No.: |
09/193973 |
Filed: |
November 18, 1998 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09193973 |
Nov 18, 1998 |
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08993468 |
Dec 18, 1997 |
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Current U.S.
Class: |
623/17.12 |
Current CPC
Class: |
A61F 2002/30016
20130101; A61B 17/00234 20130101; A61F 2/4081 20130101; A61L
2430/38 20130101; A61F 2002/30583 20130101; C08G 18/4854 20130101;
A61F 2210/0085 20130101; A61F 2002/30024 20130101; A61F 2/4202
20130101; A61F 2230/0069 20130101; A61B 1/00165 20130101; A61F
2002/30929 20130101; A61F 2/30756 20130101; A61F 2002/4627
20130101; A61F 2250/0098 20130101; A61F 2/32 20130101; Y10S 606/907
20130101; A61L 29/041 20130101; A61F 2/945 20130101; A61B
2017/00535 20130101; A61F 2/3099 20130101; A61F 2/4601 20130101;
A61F 2002/30235 20130101; A61F 2002/444 20130101; A61F 2002/30563
20130101; A61F 2250/0019 20130101; A61B 17/16 20130101; A61F
2002/30841 20130101; A61F 2002/4233 20130101; A61L 29/06 20130101;
A61F 2/07 20130101; A61F 2/82 20130101; B01F 2101/2305 20220101;
A61F 2/442 20130101; A61F 2/38 20130101; A61B 17/7097 20130101;
A61F 2/30767 20130101; A61F 2002/30601 20130101; A61L 27/18
20130101; C08G 18/69 20130101; A61F 2002/3008 20130101; A61F
2002/4635 20130101; A61B 17/17 20130101; Y10S 606/91 20130101; C08G
18/10 20130101; A61F 2/28 20130101; A61F 2/441 20130101; A61F
2250/0021 20130101; A61F 2/4611 20130101; A61F 2002/30578 20130101;
A61F 2002/30957 20130101; A61L 27/18 20130101; C08L 83/04 20130101;
A61L 27/18 20130101; C08L 75/04 20130101; A61L 29/041 20130101;
C08L 23/00 20130101; A61L 29/06 20130101; C08L 67/02 20130101; C08G
18/10 20130101; C08G 18/3206 20130101 |
Class at
Publication: |
623/17.12 |
International
Class: |
A61F 002/44 |
Claims
What is claimed is:
1. A method for repairing a tissue site, the method comprising the
steps of: (a) providing a curable polyurethane biomaterial
composition comprising a plurality of parts adapted to be mixed at
the time of use in order to provide a flowable composition and to
initiate cure, (b) mixing the composition parts in order to
initiate cure and employing minimally invasive means to deliver a
quantity of the curing composition to the tissue site, and (c)
completely curing the delivered composition to provide a permanent
repair of the tissue site.
2. A method according to claim 1 wherein the composition parts
comprise: (1) a quasi-prepolymer component comprising the reaction
product of one or more polyether polyols, one or more isocyanates,
and one or more reactive hydrophobic additives, and (2) a curative
component comprising one or more polyether polyols, one or more
chain extenders, and one or more catalysts, wherein the composition
is sufficiently flowable to permit it to be delivered to the tissue
site by minimally invasive means and there undergo complete cure in
situ under physiologically acceptable conditions in order to
provide a biocompatible material.
3. A method according to claim 2 wherein the composition provides
improved cure characteristics and cured properties as compared to a
comparable composition lacking the reactive hydrophobic additive
component.
4. A method according to claim 3 wherein the improved cure
characteristics include a significant reduction in the appearance
of bubbles when cured in the presence of moisture.
5. A method according to claim 1 wherein the curing composition
provides an induction period of about thirty seconds to two minutes
and a set time of about 3 minutes to about 15 minutes following
mixing.
6. A method according to claim 1 wherein the method is used to
repair an orthopedic joint selected from the group consisting of
diarthroidal and amphiarthroidal joints.
7. A method according to claim 6 wherein the amphiarthroidal joints
are selected from the group consisting of synphysoidal joints and
syndemoidal joints.
8. A method according to claim 7 wherein the synphysiodal joints
are intervertebral joints.
9. A method according to claim 6 wherein the method is performed
using endoscopic/arthroscopic surgical instrumentation and under
fiberoptic visualization.
10. A method according to claim 9 wherein the instrumentation
comprises a static mixer and delivery cannula to mix and deliver
the composition.
11. A curable polyurethane composition comprising a plurality of
parts capable of being mixed at the time of use in order to provide
a flowable composition and to initiate cure, the parts comprising:
(1) a quasi-prepolymer component comprising the reaction product of
one or more polyether polyols, one or more isocyanates, and one or
more reactive hydrophobic additives, and (2) a curative component
comprising one or more polyether polyols, one or more chain
extenders, and one or more catalysts, wherein the composition is
sufficiently flowable to permit it to be delivered to a tissue site
by minimally invasive means and there undergo complete cure in situ
under physiologically acceptable conditions in order to provide a
biocompatible material.
12. A composition according to claim 11 wherein the composition
provides improved cure characteristics and cured properties as
compared to a comparable composition lacking the reactive
hydrophobic additive.
13. A composition according to claim 12 wherein the hydrophobic
polymer additive is present at a concentration of between about 1%
and about 50% by weight, and is selected from the group consisting
of hydroxyl- or amine-terminated compounds selected from the group
consisting of poybutadiene, polyisoprene, polyisobutylene,
silicones, polyethylenepropylenediene, copolymers of butadiene with
acryolnitrile, copolymers of butadiene with styrene, copolymers of
isoprene with acrylonitrile, copolymers of isoprene with styrene,
and mixtures thereof.
14. A composition according to claim 12 wherein the improved cure
characteristics include a significant reduction in the appearance
of bubbles when cured in the presence of moisture.
15. A composition according to claim 11 wherein the curing
composition provides an induction period of about thirty seconds to
two minutes and a set time of about 3 minutes to about 15 minutes
following mixing.
16. A composition according to claim 12 wherein the improved cured
properties include a hardness of about 60 Shore to about 95 Shore,
and a tensile strength (measured in the dry stage) of between about
6,000 psi and about 10,000 psi.
17. A composition according to claim 13 wherein, within the
prepolymer, the polyether component is present at a concentration
of between about 2% and about 10%, by weight, based on the weight
of the composition, and is selected from the group consisting of
linear or branched polyols with polyether backbones of
polyoxyethylene, polyoxypropylene, and polytetramethylene oxide
(polyoxytetramethylene), and copolymers thereof.
18. A composition according to claim 17 wherein the polyol
comprises one or more polytetramethylene oxides having molecular
weights in the range of 250 to 2900.
19. A composition according to claim 13 wherein the isocyanate is
present in excess in the prepolymer component and comprises an
aromatic (poly)isocyanate selected from the group consisting of
2,2'- , 2,4'-, and 4,4'-diphenylmethanediisocyanate (MDI), and
combinations thereof.
20. A kit comprising a plurality of compositions according to claim
11, the compositions providing different hardnesses in their cured
form, for use in preparing a heterogeneous implant.
21. A method according to claim 1, wherein the method comprises the
further steps of: a) providing an implantable mold apparatus
comprising an expandable cavity adapted to receive and contain the
flowable biomaterial composition and a conduit adapted to connect
the cavity to a source of curable, flowable biomaterial
composition, b) inserting the mold apparatus to the tissue site, c)
mixing and delivering biomaterial composition to the mold in order
to fill the cavity to a desired extent, d) permitting the
biomaterial composition to completely cure, and e) employing the
molded biomaterial in situ as a prosthesis at the tissue site.
22. A method according to claim 21 wherein the steps of inserting
the mold apparatus, delivering the biomaterial composition, and
curing the composition are each performed by minimally invasive
means.
23. A method according to claim 21 wherein the cavity is provided
in the form of an inflatable balloon and the method is used to
prepare an intact prosthesis.
24. A method according to claim 23 wherein the method is used to
repair an intervertebral disc.
25. A method according to claim 23 wherein the method is used to
resurface a knee.
26. A method according to claim 21 wherein the cavity is provided
in tubular form and the method is used to prepare a tubular
implant.
27. A method according to claim 26 wherein the tubular implant is
used to form an implant selected from the group consisting of
stents, shunts and grafts.
28. A method according to claim 27 wherein the tubular implant
comprises a prosthetic implant for repairing an abdominal aortic
aneurysm.
29. A method according to claim 21 wherein the composition parts
comprise: (1) a quasi-prepolymer component comprising the reaction
product of one or more polyether polyols, one or more isocyanates,
and one or more reactive hydrophobic additives, and (2) a curative
component comprising one or more polyether polyols, one or more
chain extenders, one or more catalysts, wherein the composition is
sufficiently flowable to permit it to be delivered to the tissue
site by minimally invasive means and there undergo complete cure in
situ under physiologically acceptable conditions in order to
provide a biocompatible material.
30. A method according to claim 29 wherein the curing composition
provides an induction period of about thirty seconds to two minutes
and a set time of about 3 minutes to about 15 minutes following
mixing.
31. A mold apparatus for forming a prosthesis in situ, the
apparatus comprising an implantable, expandable cavity adapted to
receive and contain a flowable, curable biomaterial, and a
removable conduit adapted to connect the cavity to a source of
flowable biomaterial.
32. An apparatus according to claim 31, wherein the apparatus is
adapted for use by minimally invasive means and the cavity is a
provided in the form of an inflatable balloon for use in preparing
an intact prosthesis.
33. An apparatus according to claim 32 wherein the balloon is
adapted for use in repairing an intervertebral disc.
34. An apparatus according to claim 33 wherein the apparatus
further comprises an air passageway positioned to vent the balloon
in the course of filling with biomaterial.
35. An apparatus according to claim 33 further comprising distal
control valves for the biomaterial conduit and air passageway,
respectively.
36. An apparatus according to claim 32 wherein the balloon provides
a knee prosthesis and is adapted to be permanently positioned and
filled in apposition to subchondral bone.
37. An apparatus according to claim 36 wherein the balloon
comprises a surface for contact with subchondral bone, the surface
being provided with one or more foot pads adapted to be implanted
into corresponding anchor points drilled within subchondral
bone.
38. An apparatus according to claim 36 wherein the balloon
comprises a surface for contact with subchondral bone, the surface
being fenestrated in order to permit the passage of biomaterial
from the cavity to contact with the subchondral bone.
39. A surgical kit comprising an apparatus according to claim 37 in
combination with a template for use in drilling anchor points in
subchondral bone at positions corresponding to those of foot pads
on the apparatus.
40. A surgical kit for use in preparing a prosthesis in vivo, the
kit comprising (a) an implantable mold apparatus comprising an
expandable cavity adapted to receive and contain a flowable,
curable biomaterial, and a removable conduit adapted to connect the
cavity to a source of curable, flowable biomaterial and (b) a
supply of a curable, flowable polyurethane biomaterial
composition.
41. A prosthesis for repairing an intervertebral disc, the
prosthesis comprising an expanded mold cavity containing a cured,
biocompatible, polyurethane biomaterial composition, the prosthesis
providing a hardness of about 60 Shore to about 95 Shore, and a
tensile strength (measured in the dry stage) of between about 6,000
psi and about 10,000 psi.
42. A prosthesis for repairing the surface of a knee joint, the
prosthesis comprising a cured, biocompatible, polyurethane
biomaterial composition providing a hardness of about 60 Shore to
about 95 Shore, and a tensile strength (measured in the dry stage)
of between about 6,000 psi and about 10,000 psi.
43. A prosthesis according to claim 42 wherein the prosthesis is
heterogeneous, comprising a plurality of cured polyurethane
compositions, in order to provide layers having one or more
different properties.
44. A prosthesis according to claim 42 wherein the cured
biomaterial is provided within a mold cavity and the prosthesis is
adapted to be permanently positioned in apposition to subchondral
bone.
45. A prosthesis according to claim 43 wherein the mold cavity is
provided in the form of a balloon comprising a surface for contact
with subchondral bone, the surface being provided with one or more
foot pads adapted to be implanted into corresponding anchor points
drilled within subchondral bone.
Description
TECHNICAL FIELD
[0001] The present invention relates to methods, apparatuses,
materials and systems for the repair of musculoskeletal injury, and
in particular, for bone and cartilage repair and replacement.
[0002] In another aspect, the invention relates to polymeric
compositions, and to minimally invasive methods and materials for
the preparation of prosthetic implants and the replacement or
repair of joints and joint surfaces within the body. In another
aspect the invention relates to in situ curable compositions, such
as polymer compositions, useful for such purposes.
[0003] In yet another aspect, the present invention relates to
medical prostheses for use in in vivo applications, to methods of
preparing and delivering such prostheses, and to materials useful
for fabricating or preparing prostheses. In a further aspect, the
invention relates to the preparation of prostheses in situ.
BACKGROUND OF THE INVENTION
[0004] The musculoskeletal system is subject to injury caused by
traumatic events as well as by a number of diseases, such as
osteoarthritis and rheumatoid arthritis.
[0005] Repair of connective tissue of the musculoskeletal system is
commonly performed using materials such as natural or synthetic
tendons and ligaments. Joint repair and replacement is typically
accomplished using metal and/or polymeric implants and devices.
Such devices are typically fixated into existing bone by means of
bone plates, adhesives, screws, and the like.
[0006] The joints of the body can be classified as between those
that provide immovable articulations (synarthroidal), mixed
articulations (amphiarthroidal), and movable articulations
(diarthroidal). The ability of amphiarthroidal and diarthroidal
joints to provide effective and pain-free articulation, and/or to
serve their weight-bearing function, is generally dependent on the
presence of intact, healthy cartilage (e.g., fibrocartilage or
hyaline cartilage) within the joint.
[0007] Total joint replacement is indicated under conditions in
which the cartilage surface between the bones forming ajoint has
degenerated. Often it has degenerated to a point where there is
significant pain during locomotion, as well as during translation
and rotation of joint components. Such degenerative joint disease
is commonly treated by a technique known as total joint replacement
arthroplasty, which is typically an invasive procedure that
involves replacement of the original surfaces with artificial
weight bearing materials in the form of implants.
[0008] Hip replacement generally involves the implantation of a
femoral component in the form of a ball mounted on a shaft,
together with an acetabular component in the form of a socket into
which the ball sits.
[0009] Total knee replacement is somewhat more difficult than hip
replacement because of the complex loading pattern of the knee. The
tibial component of a total knee replacement is fixed in the
cancellous bone of the tibia. The femoral component is typically
fixed to the cortical bone of the femoral shaft using a suitable
cement.
[0010] The tibial portion of a knee prosthetic device generally
involves the insertion of a broad plateau region covering the
tibia, after bone of the subchondral plate is removed. In most
designs, a composite material is provided, involving a metal
support underlying a polymeric, or fiber-reinforced polymeric
tray.
[0011] A wide array of materials have been described for use in the
manufacture of medical implants. See generally, Chapter 1, in
Biomaterials, Medical Devices and Tissue Engineering: An Integrated
Approach, Frederick H. Silver, ed., Chapman and Hall, 1994. Such
materials generally fall into the categories of metals, polymers,
ceramics, and composite materials.
[0012] A recent article entitled "New Challenges in Biomaterials",
Science, 263:1715-1720 (1994), Peppas et al., provides a useful
overview of the current state of the art in biomaterials. The
article describes a number of materials currently used for
orthopedic applications, including metals (iron, cobalt, and
titanium), degradable polymers, self-reinforced compositions of
polyglycolic acid, stronger polymers such as polydioxanone, and
ceramic materials such as hydroxyapatite and certain glasses.
[0013] Elsewhere, for instance at page 1719, the Peppas et al.
article refers to the potential usefulness of polymers that can be
triggered to undergo a phase change. The article itself does not
identify such polymers, but instead postulates that materials that
are initially liquid might be administered through a minimally
invasive surgical device and then triggered to solidify or gel in
the presence of ultraviolet light, visible light, or ionic change
in vivo. As an example of this approach the article cites an
article of Hill-West, et al., Obstet. Gynecol. 83(1):59-64
(1994).
[0014] The Hill-West et al. article, in turn, describes the use of
a conformable, resorbable hydrogel barrier for preventing
postoperative adhesions in animals. The article describes the
formation of the hydrogel barrier in situ by photopolymerizing a
solution of a macromolecular prepolymer using UV light. The
hydrogel barrier is not described as being useful in
weight-bearing, orthopedic applications, and in fact, was
completely resorbed within 7 days after application.
[0015] There are a number of drawbacks associated with the
biomaterials and related methods presently employed for orthopedic
applications, and in particular joint repair and replacement. One
such drawback is that these methods generally involve invasive
surgery, i.e., resecting tissue in order to gain access to the
injury site. In turn, invasive surgery typically involves up to 7
to 10 days of hospitalization, with the costs associated
therewith.
[0016] A related drawback of an arthrotomy involves the need to cut
through skin, nerves, vessels, muscles, ligaments, tendons, and/or
joint capsules. Certain procedures can also require the use of
either general or spinal anesthesia. They may also require blood
transfusions and significant recovery time accompanied by
post-surgical pain and discomfort. Lastly, prolonged physical
therapy is typically required to strengthen operative areas and
prevent contractures. Such therapy can often last up to six weeks
or more.
[0017] It would be particularly useful to be able to repair such
injuries in a manner that avoided such invasive surgical procedures
and the problems associated therewith.
[0018] A number of approaches, and in turn compositions, are
currently employed for such purposes as preparing prosthetic
implants and repairing damaged joints and joint cartilage. Such
approaches include the widespread use of artificial prosthetic
implants that can be formed of an array of materials such as
metals, ceramics, and bioerodible or resorbable materials. Indeed,
the manufacture and use of such implants has grown exponentially in
recent decades. See, for instance, "New Challenges in
Biomaterials", Science, 263:1715-1720 (1994), Peppas et al.
[0019] Similarly, a number of references, and particularly those in
the dental area, have described methods or apparatuses for the
delivery and cure of materials within the oral cavity. Outside of
the dental area, however, the number of such applications is far
more limited, and includes such references as Perkins et al. (U.S.
Pat. No. 4,446,578) and Oechsle III (U.S. Pat. No. 4,570,270
polyurethanes as luting agents for filling cavities in bones). See
also, Kuslich (U.S. Pat. No. 5,571,189 expandable fabric spine
implant device in combination with a `graft medium` to promote
fibrous union of joints); Parsons et al. (U.S. Pat. No. 5,545,229
intervertebral disc spacer formed of an elastomeric material in
nucleus and annulus); Porter et al. (U.S. Pat. No. 5,591,199
curable fiber composite stent, fibrous material treated with
curable material to form curable fiber composite); Glastra (U.S.
Pat. No. 5,529,653 expandable double walled sleeve, space filled
with curable material; and Cowan (U.S. Pat. No. 5,334,201 vascular
reinforcing stent having tubular sleeve of a cross-linkable
substance, the sleeve being encapsulated within a biocompatible
film).
[0020] Even more recently, Applicant's U.S. Pat. No. 5,556,429
describes ajoint resurfacing system which, in a preferred
embodiment, involves the use of minimally invasive means to access
and prepare a joint site, such as a knee, and to deliver a curable
biomaterial to the prepared site and cure the biomaterial in
apposition to the prepared site. The system includes the use of
curable biomaterials such as silicone polymers and polyurethane
polymers.
[0021] Polyurethanes themselves have been developed and used since
at least the 1940's for the preparation of a variety of materials,
including cast polyurethane rubbers and millable gums. Cast
polyurethane rubbers can be subdivided into four general groups,
including 1) unstable prepolymer systems, 2) stable prepolymer
systems, 3) quasi-prepolymer systems, and 4) "one-shot" systems.
See, for instance, "Polyurethanes and Polyisocanurates", Chapter 27
in Plastics Materials, J. Brydson, ed., 6th ed. Butterworth
Heeinemann (1995).
[0022] Generally, such compositions involve the reaction of a
polyhydroxy material (polyol) with an isocyanate to provide a
polyurethane material. A limited number of references describe the
use of components such as hydroxyl-terminated butadiene in the
context of a polyurethane. Khalil, et al. (U.S. Pat. No.
5,288,797), for instance, describe moisture curable polyurethane
adhesive compositions in the form of a blend of polyurethane
prepolymers, together with additives (such as carbon black) and a
resin, which are used to improve mechanical properties such as sag
resistance. The list of polyols described as being useful for
forming the prepolymer is said to include polybutadiene having at
least two terminal primary and/or secondary hydroxyl groups.
[0023] Similarly, Graham et al. (U.S. Pat. No. 4,098,626) describes
a hydroxy terminated polybutadiene based polyurethane bound
propellant grains, while Chapin et al. (U.S. Pat. No. 4,594,380)
describe an elastomeric controlled release article having a matrix
formed of a polyurethane that itself is the reaction product of an
isocyanate and a polyol selected from a group that includes
hydroxyl-terminated polybutadiene.
[0024] While materials such as those described above are useful for
their intended purposes, and have created new opportunities in
their respective fields, it would be desirable to further improve
various properties associated with such materials. With regard to
their use as in vivo curable biomaterials, for instance, certain
polyurethane compositions have been found to produce undesirable
bubbles when delivered and cured in the presence of moisture.
Improvement of this and other properties would be highly desirable,
provided such improvement can be accomplished without undue effect
on other desired and necessary properties. It would be highly
desirable to have a polyurethane composition that improves the
moisture cure characteristics and other properties of such a
material, without detrimental effect on other necessary and
preferred properties.
[0025] The development of implantable medical devices has grown
dramatically over past decades. Correspondingly, those developing
new and useful biomaterials for use in fabricating such devices
have attempted to keep pace. The implantable medical devices can
themselves take a wide variety of forms and purposes.
[0026] Many prostheses are used to replace or repair orthopedic
joints. The joints of the body can be classified as between those
that provide immovable articulations (synarthroidal), mixed
articulations (amphiarthroidal), and movable articulations
(diarthroidal). The ability of amphiarthroidal and diarthroidal
joints to provide effective and pain-free articulation, and/or to
serve their weight-bearing function, is generally dependent on the
presence of intact, healthy cartilage within the joint.
[0027] Conventional joint prostheses are generally fabricated by
the manufacturer, often as component parts of varying sizes, and
selected and implanted by the surgeon in the course of invasive
surgery. The applicant of the present invention, however, has
demonstrated the manner in which curable biomaterials can be used
to repair or resurface ajoint. See, for instance, U.S. Pat. No.
5,556,429. This patent describes, for instance, the use of
minimally invasive means to deliver and cure a biomaterial at a
prepared site such as the knee, as well as the optional use of
holes drilled into the bone, e.g., subchondral bone, that can be
filled with the biomaterial to provide anchor points once
cured.
[0028] The delivery of such biomaterials can take the shape of the
prepared site, or can further incorporate the use of a mold, e.g.,
in the manner described in Applicant's corresponding PCT Patent
Application No. PCT/US97/00457. In one such embodiment, for
instance, a mold is provided in the form of a balloon that can be
delivered to the site of an intervertebral disc space, and there
filled with biomaterial in order to serve as a replacement
disc.
[0029] Other examples of implanted or implantable devices include
Kuslich (U.S. Pat. No. 5,571,189); Kuslich (U.S. Pat. No.
5,549,679); Parsons et al. (U.S. Pat. No. 5,545,229); Oka (U.S.
Pat. No. 5,458,643); Baumgartner (U.S. Pat. No. 5,171,280); Frey et
al. (U.S. Pat. No. 4,932,969); Ray et al. (U.S. Pat. No.
4,904,260); Monson (U.S. Pat. No. 4,863,477); and Froning (U.S.
Pat. No. 3,875,595).
[0030] Implantable medical prostheses can take other forms as well,
including other traditional types that are fabricated and packaged
prior to use, and implanted in either a transitory, temporary or
permanent fashion within the body. Such prostheses can be used, for
instance, as or in connection with passageways within the body such
as catheters, such as stents and shunts. Other examples of devices
implantable on at least a transitory basis include catheters such
as balloon catheters. See, for example, the following U.S. Patents
to Walinsky (U.S. Pat. No. 5,470,314); Saab (U.S. Pat. No.
5,411,477); Shonk (U.S. Pat. No. 5,342,305); Trotta et al. (U.S.
Pat. No. 5,290,306); Tower (U.S. Pat. No. 4,913,701); Oechsle III
(U.S. Pat. No. 4,570,270); and Perkins et al. (U.S. Pat. No.
4,446,578).
[0031] The use of stents, in particular, has become accepted as a
means for preventing abrupt vessel closure and restenosis following
balloon angioplasty and over the past decade has grown dramatically
as problems inherent in early designs have been overcome.
Typically, stents are constructed from nonthrombogenic materials of
sufficient flexibility (in their unexpanded state) to allow passage
through guiding catheters and tortuous vessels. Such stents are
typically radiopaque to allow fluoroscopic visualization. To date,
most coronary stents have been constructed from either stainless
steel or titanium, e.g., in the form of an expandable mesh, wire
coil, slotted tube, or zigzag design.
[0032] Recent developments have included the use of
balloon-expandable stents. Such stents are available in a number of
configurations, such as the Gianturco-Roubin Flex-Stent (Cook,
Inc.), the Pahnax-Schatz Coronary Stent (Johnson & Johnson),
Wiktor Stent (Medtronic, Inc.), Strecker Stent (Boston Scientific),
ACS Multi Link Stent (Advanced Cardiovascular Systems, Inc.) the
AVE Micro Stent (Applied Vascular Engineering) and Cordis Stent
(Cordis Corp.). Even more recently, temporary stents (e.g.,
removable or biodegradable) have been developed, in an effort to
achieve the structural support and lumen stabilizing benefits of
permanent stenting without the problem of thrombosis.
[0033] Most stents, and certainly most, if not all, commercially
available stents, are manufactured and sterilized by the
manufacturer, and provided in an insertable form. Other approaches
have been described, however, including modification of the stent
material either pre- or post-delivery. See, e.g., Porter et al.,
U.S. Pat. Nos. 5,591,199 (for a "Curable Fiber Composite Stent and
Delivery System"). In spite of recent accomplishments, many stents
available today continue to encounter problems upon insertion
(e.g., lack of flexibility) and/or over the course of their use
(e.g., erosion, tissue incompatability).
[0034] In a similar manner, a variety of preformed catheters and
shunts have been developed in the form of tubular instruments to
allow passage of fluid from, into, or between body cavities.
Relatively few of the many known catheters are formed or prepared
in situ. Recent patents of Glastra (U.S. Pat. Nos. 5,344,444 and
5,529,653) describe, for instance, a method for the fabrication and
use of an expandable hollow sleeve for local support or
reinforcement of a body vessel. The hollow sleeve is described as
having a curable material, such as an "acrylate", contained within
an absorbent material within the sleeve. In a different approach,
Cowan (U.S. Pat. No. 5,334,201) describes a stent made of a
crosslinkable material, by a method that involves encapsulating an
uncured stent in a biologically compatible film, transluminally
inserting the stent/filn into position, and curing the stent.
[0035] Preformed catheters and grafts have also been used in the
treatment of abdominal aortic aneurysms. The ultimate goal in the
treatment of aortic aneurysms is to exclude the aneurysm from the
aortic bloodstream without interfering with limb and organ
perfusion. Direct surgical repair of such aneurysms is associated
with high morbidity and mortality. The technique of placing a
prosthetic graft into the opened aneurysm and suturing it to
"normal" aorta above and below requires extensive intraabdominal or
retroperitoneal dissection, as well as interruption of blood flow
during completion of the anastomoses, under general anesthesia.
[0036] Methods and materials used to prepare implantable
prostheses, as described above, can be contrasted to those used in
the burgeoning dental field, in which polymers play an important
role as ingredients of composite restorative materials, cements and
adhesives, cavity liners and protective sealants. See, for
instance, Brauer and Antonucci, "Dental Applications" pp 257-258 in
Concise Encyclopedia of Polymer Science and Engineering.
[0037] At times, the preparation of such dental prostheses relies
on the use of molds taken of parts of the body in order to then
cast or otherwise form prosthetic replacement parts. See, for
instance, Weissman, U.S. Pat. No. 4,368,040 for "Dental impression
tray for forming a dental prosthesis in situ". See also, "Process
for making a prosthetic implant", Kaye U.S. Pat. No. 5,156,777,
which involves the use of three-dimensional data to prepare a life
size model of an organ site, which in turn is used to cast a
prosthetic implant.
[0038] Clearly the ability to mold body parts, such as teeth, in
order to form prosthetic devices is considerably different than the
preparation and delivery of preformed implants themselves,
particularly for implants used in internal sites or tissues that
are not as readily accessible as the oral cavity. Among the several
distinctions between preformed implantable prostheses and those
formed in situ are the fact that the latter are typically
restricted to external or surgically accessible sites or tissues.
In these situations, the ability to deliver a material used to form
a prosthesis at an accessible site, although certainly demanding in
many respects, has far fewer considerations than a material
intended for delivery and use internally.
[0039] A number of problems that continue to affect the further
development of some or all of the above-described implanted
prostheses, include problems that affect the preparation of the
prostheses themselves, their delivery to the site of use, and their
interactions with the host or surrounding tissue in the course of
their use.
[0040] For example, the physician cannot correct the size and shape
of the prostheses once it has been introduced to the body;
therefore, all measurements and adjustments of size must be made
preoperatively. In the case of aortic grafts, the aorta may
continue to enlarge and thus pull away from the fixation stent.
Problems associated with the healing interface between the stent,
the graft, and the aorta is not known, and the graft may dislodge
and migrate, causing acute iliac occlusion. The aneurysm may
continue to function despite an intact functioning endovascular
graft.
[0041] It would clearly be desirable to have a system that permits
prostheses to be prepared and used in a manner that overcomes some
or all of these concerns.
SUMMARY OF THE INVENTION
[0042] The present invention overcomes the drawbacks associated
with the prior art by providing a method, and related composition
and apparatus for repairing or resurfacing the site of injured
tissue by minimally-invasive means.
[0043] In one embodiment, the method of the present invention
comprises the steps of:
[0044] (a) providing a curable biomaterial; and
[0045] (b) employing minimally invasive means to:
[0046] (i) prepare the tissue injury site for receipt of the
biomaterial;
[0047] (ii) deliver a quantity of the curable biomaterial to the
prepared tissue injury site;
[0048] (iii) cure the delivered biomaterial in such a manner that
the cured biomaterial is permanently retained in apposition to the
prepared site; and
[0049] (iv) contour the cured, retained biomaterial to achieve a
desired conformation approximating that of natural tissue.
[0050] The method of the invention lends itself to a corresponding
system that comprises curable biomaterial, in combination with
minimally invasive means for preparing the tissue site; delivering
the biomaterial to the prepared tissue site; curing the biomaterial
in situ; and contouring the cured biomaterial. The individual
components of such a system, and particularly means for delivering
and curing biomaterial in a minimally invasive fashion are
considered novel as well.
[0051] In a preferred embodiment, a system is provided that
comprises: (a) an arthroscopic surgical instrument; and (b) a fluid
delivery cannula capable of delivering a flowable, curable
biomaterial under arthroscopic visualization, the biomaterial
comprising a curable polymer and hydrogel.
[0052] The preferred system can be used to perform a method that
comprises the steps of:
[0053] (a) providing a flowable, curable biomaterial comprising a
curable biomaterial;
[0054] (b) preparing the tissue injury site by operation of the
arthroscopic instrument, and under arthroscopic visualization;
[0055] (c) preparing a tissue access site to include anchor points
in the subchondral bone and inserting and directing the delivery
cannula through the tissue access site to the site of tissue
injury;
[0056] (d) delivering a quantity of the curable biomaterial through
the cannula to the prepared site;
[0057] (e) curing the delivered biomaterial by minimally invasive
means and in a manner such that the cured biomaterial is retained
in apposition to the prepared site; and
[0058] (f) contouring the cured biomaterial to achieve a desired
conformation approximating that of natural tissue.
[0059] In an alternative embodiment, the cured, shaped biomaterial
can be treated or modified in order to improve one or more
desirable properties, for instance, it can be coated with a
permanent interface material in order to improve the
biocompatibility or coefficient of friction of the final
implant.
[0060] In another aspect, the present invention provides a curable
polyurethane composition comprising a plurality of parts capable of
being sterilized, stably stored, and mixed at the time of use in
order to provide a flowable composition and initiate cure, the
parts including: (1) a quasi-prepolymer component comprising the
reaction product of one or more polyether polyols, one or more
isocyanates, and one or more reactive hydrophobic additives, and
(2) a curative component comprising one or more polyether polyols,
one or more chain extenders, one or more catalysts, and optionally,
other ingredients such as an antioxidant and dye. Upon mixing, the
composition is sufficiently flowable to permit it to be delivered
to the body by minimally invasive means, and there fully cured
under physiologically acceptable conditions. Preferably, the
component parts are themselves flowable, or can be rendered
flowable, in order to facilitate their mixing and use.
[0061] Applicants have discovered, inter alia, that the presence of
the reactive hydrophobic additive of the prepolymer provides
several unexpected and desirable features, both in the formulation
and use of the prepolymer itself, as well as in the mixed
composition. These features include an improved combination of such
properties as moisture cure characteristics, crosslinking,
viscosity, compression fatigue, and stability. In particular, the
use of the polymer significantly lessens, and can avoid altogether,
the appearance of bubbles seen previously with polyurethane
compositions cured in vivo in the presence of moisture. While not
intending to be bound by theory, it appears that the presence of a
sufficient amount of hydrophobic or nonpolar additive, and
particularly one that is miscible with the polyether component,
alters or affects the surface tension (e.g., as determined by the
contact angle) of the resulting composition, and in turn, permits
the composition to cure with a significant reduction in the
appearance of bubbles. Surprisingly, this and other improved
characteristics are not achieved at the sacrifice of other
desirable properties.
[0062] In a preferred embodiment, within the prepolymer, the
polyether component is present at a concentration of between about
2% and about 10%, and preferably between about 4% and about 8% by
weight, based on the weight of the composition, and is selected
from the group consisting of linear or branched polyols with
polyether backbones of polyoxyethylene, polyoxypropylene, and
polytetramethylene oxide (polyoxytetramethylene), and copolymers
thereof. A particularly preferred polyol is polytetramethylene
oxide, preferably of relatively low molecular weights in the range
of 250 to 2900, and combinations thereof.
[0063] In a further preferred embodiment the isocyanate is present
in excess in the prepolymer component, e.g., at a concentration of
between about 30% and about 50%, and preferably between about 35%
and about 45%, by weight. The isocyanate is preferably an aromatic
(poly)isocyanate selected from the group consisting of 2,2'-,
2,4'-, and 4,4'-diphenylmethanediisocyanate (MDI), and combinations
thereof.
[0064] In such an embodiment, the reactive polymer additive itself
is present at a concentration of between about 1% and about 50% by
weight, and is selected from the group consisting of hydroxyl- or
amine-terminated compounds selected from the group consisting of
poybutadiene, polyisoprene, polyisobutylene, silicones,
polyethylenepropylenediene, copolymers of butadiene with
acryolnitrile, copolymers of butadiene with styrene, copolymers of
isoprene with acrylonitrile, copolymers of isoprene with styrene,
and mixtures of the above. In a particularly preferred embodiment
the additive comprises hydroxyl-terminated polybutadiene, present
at a concentration of between about 5% and about 30%, by weight,
and preferably between about 5% and about 20% by weight.
[0065] In a further preferred embodiment, the polyether polyol of
the curative component is as described above with regard to the
prepolymer and is present at a final concentration of between about
20% and 60%, and preferably between about 30% and about 45%, by
weight. In such an embodiment, the chain extender comprises a
combination of linear (e.g., cyclohexane dimethanol ("CHDM")) and
branched (e.g, trimethyloyl propane ("TMP") chain extenders, with
the former being present at a final concentration of between about
1% and 20% (and preferably between about 5% and about 15%), and the
latter being present at a final concentration of between about 1%
and about 20%, and preferably between about 1% and about 10%, by
weight of the final composition.
[0066] Surprisingly, the composition provides improved properties,
including an improved combination of such properties as hardness,
strength and/or cure characteristics (particularly in the presence
of moisture), as compared to compositions previously known. More
surprisingly, Applicants have discovered that such improvement can
be achieved without detrimental effect on other desired properties,
including those that arise (a) prior to delivery, (b) in the course
of delivery (including whatever mixing, curing, and/or shaping that
may occur), and finally, (c) following cure and in the course of
extended use in the body.
[0067] In another aspect, the invention provides a cured
composition, prepared as the reaction product of a plurality of
parts as described herein. In yet another aspect, the invention
provides a kit that can be used to prepare a composition and/or
that itself includes a composition as a component part. A kit, for
instance, may take the form of a composition (or its components) in
combination with preformed device components or accessories, such
as an implantable mold apparatus for shaping and restraining the
composition. Optionally, a kit can also include a composition (or
its components or parts) in combination with a delivery device
adapted to deliver the composition to the site of tissue injury.
Optionally, a kit may also take the form of a composition, either
as its component parts and/or in combination with other ingredients
or materials, such as a filler or hydrogel (used to form a matrix),
or together with an implantable prosthetic device. In any such kit,
it is envisioned that a kit may include one or more protocols or
instructions for use.
[0068] In yet another aspect, the invention provides a method of
preparing and a method of using such a composition. In a further
aspect, the invention provides a cured composition (optionally
within a mold apparatus), for use in apposition to a joint surface,
as well as the combination of such a joint surface with a cured
composition (optionally within a mold apparatus) in apposition
thereto.
[0069] In yet another aspect, the present invention provides an
apparatus and method for forming a prosthesis, in situ, the method,
in a preferred embodiment, comprising the steps of:
[0070] a) providing an implantable mold apparatus comprising a
cavity adapted to receive and contain a flowable biomaterial and a
conduit adapted to connect the cavity to a source of curable,
flowable biomaterial,
[0071] b) inserting the mold, preferably by minimally invasive
means, to a desired site within the body,
[0072] c) delivering biomaterial to the mold in order to fill the
cavity to a desired extent,
[0073] d) permitting the biomaterial to cure to a desired extent,
and
[0074] e) employing the molded biomaterial in situ as a prosthetic
device.
[0075] The apparatus, in turn, provides an implantable mold
apparatus comprising an expandable cavity adapted to receive and
contain a flowable biomaterial in a geometry, configuration and/or
position optimal for the intended purpose, and a conduit adapted to
connect the cavity to a source of curable, flowable biomaterial.
The conduit is preferably removable from the filled cavity, e.g.,
by cutting it at or near the point where it joins the cavity.
Optionally, and preferably, the apparatus further includes means
for providing positive or negative air pressure within or to the
biomaterial cavity, in order to facilitate the delivery of
biomaterial and/or to affect the final shape of the cured mold.
[0076] The apparatus and method can be used for a variety of
applications, including for instance, to provide a balloon-like
mold for use preparing a solid or intact prosthesis, e.g., for use
in articulating joint repair or replacement and intervertebral disc
repair. Alternatively, the method can be used to provide a hollow
mold, such as a sleeve-like tubular mold for use in preparing
implanted passageways, e.g., in the form of catheters, such as
stents, shunts, or grafts.
[0077] In yet another aspect, the invention provides a mold
apparatus useful for performing a method of the invention, e.g., in
the form of an inflatable balloon or tubular mold, preferably in
combination with the conduit used to deliver biomaterial. Along
these lines, the invention further provides a system useful at the
time of surgery to prepare an implanted prosthesis in vivo, the
system comprising a mold apparatus (e.g., cavity and conduit) in
combination with a supply of curable biomaterial, and optionally,
with a source of positive and/or negative air pressure.
[0078] In a further aspect, the invention provides a corresponding
prosthesis formed by a method of the present invention, including
for instance, an implanted knee prosthesis, intervertebral disc
prosthesis, and a tubular prosthesis for use as a catheter, such as
a stent, shunt, or graft (e.g., vascular graft). The present
invention further provides surgical kits that include a mold
apparatus as presently described, in combination with a
corresponding drilling template, and a kit in which a mold
apparatus is provided in combination with a supply (e.g.,
sufficient for a single use) of biomaterial itself.
BRIEF DESCRIPTION OF THE DRAWING
[0079] In the Drawing:
[0080] FIG. 1 shows a top plan view of a mold apparatus including a
balloon cavity and biomaterial delivery conduit for use in
intervertebral disc replacement.
[0081] FIG. 2 shows the apparatus of FIG. 1 with the balloon in its
collapsed form contained within an outer sheath, suitable for
insertion and positioning within the disc space.
[0082] FIG. 3 shows a mandrel used for forming the balloon of FIG.
1 by dip-coating the mandrel in a suitable solution of curable
polymer.
[0083] FIG. 4 shows a balloon as formed upon the mandrel shown in
FIG. 3.
[0084] FIG. 5 shows the balloon of FIG. 1 positioned within the
disc space and in the course of filling with biomaterial.
[0085] FIG. 6 shows a preferred embodiment of a mold apparatus for
use in the repair or replacement of knee cartilage.
[0086] FIG. 7 shows a drilling template for use in connection with
the apparatus of FIG. 6.
[0087] FIG. 8 shows a preferred embodiment of a mold apparatus, in
uninflated and unfilled form, in the form of a tubular system for
preparing an implanted passageway in situ.
[0088] FIG. 9 shows the mold of FIG. 8 in a form wherein relevant
portions have been filled with air and biomaterial.
[0089] FIG. 10 shows a cross section of the mold apparatus of FIG.
9, taken along lines 10-10.
DETAILED DESCRIPTION
[0090] The present invention provides a method and system for the
repair of natural tissue that involve the delivery of a biomaterial
composition using minimally invasive means, the composition being
curable in situ in order to provide a permanent replacement for
natural tissue. Optionally, and preferably, the biomaterial is
delivered to a mold apparatus that is positioned by minimally
invasive means and filled with biomaterial composition, which is
then cured in order to retain the mold and cured composition in
situ.
[0091] As used herein the following words and terms shall have the
meanings ascribed below:
[0092] "repair" will refer to the use of a composition to augment,
replace or provide some or all of the structure or function of
natural tissue in vivo, for instance, to provide an implant such as
a catheter, or to repair (e.g., reconstruct or replace) cartilage,
such as fibrocartilage or hyaline cartilage present in a
diarthroidal or amphiarthroidal joint. Repair can take any suitable
form, e.g., from patching the tissue to replacing it in its
entirety, preferably in a manner that reconstructs its natural or
other desired dimensions;
[0093] "cure" and inflections thereof, will refer to any chemical,
physical, and/or mechanical transformation that allows a
composition to progress from a form (e.g., flowable form) that
allows it to be delivered to the joint site, into a more permanent
(e.g., cured) form for final use in vivo. When used with regard to
the method of the invention, for instance, "curable" can refer to
uncured composition, having the potential to be cured in vivo (as
by catalysis or the application of a suitable energy source), as
well as to a composition in the process of curing (e.g., a
composition formed at the time of delivery by the concurrent mixing
of a plurality of composition components). As further described
herein, the cure of a composition can generally be considered to
include three stages, including (a) the onset of gelation, (b) a
period in which gelation occurs and the composition becomes
sufficiently tack-free to permit shaping, and (c) complete cure to
the point where the composition has been finally shaped for its
intended use.
[0094] "minimally invasive means" refers to surgical means, such as
microsurgical or endoscopic or arthroscopic surgical means, that
can be accomplished with minimal disruption of the pertinent
musculature, for instance, without the need for open access to the
tissue injury site or through minimal incisions (e.g., incisions of
less than about 4 cm and preferably less than about 2 cm). Such
surgical means are typically accomplished by the use of
visualization such as fiberoptic or microscopic visualization, and
provide a post-operative recovery time that is substantially less
than the recovery time that accompanies the corresponding open
surgical approach;
[0095] "endoscopic/arthroscopic surgical instrument" refers to the
controllers and associated hardware and software necessary for
performing conventional endoscopic or arthroscopic surgery; and
[0096] "delivery cannula" shall mean a cannula or other delivery
device capable of being operated in a minimally invasive fashion,
e.g., under arthroscopic visualization, and optionally together
with associated connective tubing and containers for the operable
and fluid attachment of the cannula to a source of composition for
the storage, delivery, and recovery of compositions of the present
invention.
[0097] "mold" will refer to the portion or portions of an apparatus
of the invention used to receive, constrain, shape and/or retain a
flowable biomaterial in the course of delivering and curing the
biomaterial in situ. A mold may include or rely upon natural
tissues (such as the annular shell of an intervertebral disc) for
at least a portion of its structure, conformation or function. The
mold, in turn, is responsible, at least in part, for determining
the position and final dimensions of the cured prosthetic implant.
As such, its dimensions and other physical characteristics can be
predetermined to provide an optimal combination of such properties
as the ability to be delivered to a site using minimally invasive
means, filled with biomaterial, and optionally, then remain in
place as or at the interface between cured biomaterial and natural
tissue. In a particularly preferred embodiment the mold material
can itself become integral to the body of the cured
biomaterial.
[0098] As described herein, a mold apparatus will generally include
both a cavity for the receipt of biomaterial and a conduit for the
delivery of biomaterial to that cavity. Some or all of the material
used to form the cavity will generally be retained in situ, in
combination with the cured biomaterial, while some or all of the
conduit will generally be removed upon completion of the method. An
implanted prosthesis, in turn, can be used to replace, provide, or
supplement the structure or function of natural tissue in vivo. The
prosthesis can take any suitable form, e.g., including patching,
repairing or replacing tissue (such as knee or intervertebral
disc), supporting existing tissue (as by a stent, for instance), or
creating new material having a tissue like function (as by a
shunt).
[0099] The word "biomaterial" will be used interchangeably with the
word "composition", when used in the context of the present
invention, and will generally refer to a material that is capable
of being introduced to the site of a joint and cured to provide
desired physical-chemical properties in vivo. In a preferred
embodiment the term will refer to a material that is capable of
being introduced to an site within the body using minimally
invasive means, and cured or otherwise modified in order to cause
it to be retained in a desired position and configuration.
Generally such biomaterials are flowable in their uncured form,
meaning they are of sufficient viscosity to allow their delivery
through a cannula of on the order of about 1 mm to about 6 mm inner
diameter, and preferably of about 2 mm to about 3 mm inner
diameter. Such biomaterials are also curable, meaning that they can
be cured or otherwise modified, in situ, at the tissue site, in
order to undergo a phase or chemical change sufficient to retain a
desired position and configuration.
Method and System
[0100] In a preferred embodiment, the present invention provides a
method and related materials and apparatus for repairing
diarthroidal and amphiarthroidal joints by minimally invasive
means. The method involves the use of minimally invasive means to
prepare the site of injury, deliver a curable biomaterial to the
joint site, and to cure the biomaterial in situ in order to repair
hyaline cartilage and/or fibrocartilage.
[0101] According to a preferred embodiment, a liquid phase
polymeric composite material (e.g., formed of a two-part
polyurethane system) is applied through a cannula under
arthroscopic visualization. The composite is cured and contoured in
situ to effectively resurface a damaged joint. The cured polymer
composite exhibits physical/chemical characteristics analogous to
those of human cartilage, and demonstrates an optimal combination
of such properties as load bearing, shear stress resistance, impact
absorption, and wear characteristics. The surface of the cured
composite can optionally be modified after curing and contouring,
e.g., in order to reduce its coefficient of friction.
[0102] In a preferred embodiment, the method of the present
invention comprises the step of providing a curable biomaterial
comprising a curable polymer, optionally in combination with a
hydrogel. Biomaterials suitable for use in the present invention
include those materials that are capable of being delivered by
means of a cannula, as described herein, and cured in situ in order
to form a replacement material for bone or cartilage.
[0103] Natural cartilage is a non-vascular structure found in
various parts of the body, and particularly articular cartilage,
which exists as a glycosamine matrix with a fibrillar scaffold of
Type II collagen. Chondrocytes are typically interspersed in the
matrix. Its natural elasticity enables it to break the force of
concussions, while its smoothness affords ease and freedom of
movement. In terms of thickness, cartilage tends to take on the
shape of the articular surface on which it lies. Where this is
convex, the cartilage is thickest at the center, where the greatest
pressure is received. The reverse is generally true in the case of
concave articular surfaces.
[0104] Preferred biomaterials are intended to mimic many of the
physical-chemical characteristics of natural cartilage. Preferred
biomaterials are composites of two or more individual materials,
and particularly those comprising two phase systems formed from a
polymeric matrix and a hydrogel filler. Particularly preferred
biomaterials are polyurethane systems of the type described
herein.
[0105] The method of the invention can be used to repair a number
of tissues, including a variety of joints, and is particularly
useful for diarthroidal and amphiarthroidal joints. Examples of
suitable amphiarthroidal joints include the synphysoidal joints,
such as the joints between bodies of the vertebrae. Such joints
provide surfaces connected by fibrocartilage, and have limited
motion. Other examples include syndesmoidal joints, having surfaces
united by an interosseous ligament, as in the inferior
tibio-fibular joint.
[0106] Examples of suitable diarthroidal joints include the
ginglymus (a hinge joint, as in the interphalangeal joints and the
joint between the humerus and the ulna); throchoides (a pivot
joint, as in superior radio-ulnar articulation and atlanto-axial
joint); condyloid (ovoid head with elliptical cavity, as in the
wrist joint); reciprocal reception (saddle joint formed of convex
and concave surfaces, as in the carpo-metacarpal joint of the
thumb); enarthrosis (ball and socket joint, as in the hip and
shoulder joints) and arthrodia (gliding joint, as in the carpal and
tarsal articulations).
[0107] In a particularly preferred embodiment, the method and
system of the present invention are used to resurface a joint
selected from the group consisting of enarthroidial ("ball and
socket") joints, and in particular the hip and shoulder joints, and
ginglymo-arthroidal ("hinge") joints, and in particular the
temporo-mandibular joint. Such joints provide a particularly unique
advantage in that one or more components of the natural joint can
themselves be temporarily repositioned in order to contour the
biomaterial as it cures.
[0108] A degenerative shoulder joint is repaired, for instance, by
resurfacing either the humeral head, or preferably, the glenoid
fossa. The glenoid fossa is arthroscopically exposed and the
residual cartilage is removed by burrs and cutters. Optionally, and
preferably, the humeral head is smoothed and all roughened
cartilage surfaces removed. With the patient suitably positioned, a
curable biomaterial is delivered allowed to flow smoothly into the
glenoid fossa. With the polymer in a non-tacky, but moldable stage
of cure the humeral head is repositioned into the glenoid for use
in molding the polymer as it continues to cure. In an alternative
to the use of minimally invasive means, the process can be
performed using invasive surgical procedures, given the unique
qualities of the biomaterial.
[0109] A degenerative hip joint is repaired in a similar manner,
for instance, by resurfacing either the femoral head, or
preferably, the acetabular cup. The cup is arthroscopically exposed
and the residual cartilage is removed by burrs and cutters.
Optionally, and preferably, the femoral head is smoothed and all
roughened cartilage surfaces removed. With the patient suitably
positioned, a curable biomaterial is delivered allowed to flow
smoothly into the acetabular cup. With the polymer in a non-tacky,
but moldable stage of cure the femoral head is repositioned into
the acetabulum for use in molding the polymer as it continues to
cure. In an alternative to the use of minimally invasive means, the
process can be performed using invasive surgical procedures, given
the unique qualities of the biomaterial.
[0110] A degenerative temporo-mandibular joint can be
arthroscopically repaired using two small portals. Through one
portal a needle arthroscope is placed for visualization of the
temporomandibular joint. Through the second portal the surface of
the maxillar portion is prepared and the mandible ramus surface is
smoothed. Optionally, anchor points are cut in the maxilla. With
the patient suitably positioned, a curable biomaterial is delivered
and allowed to flow smoothly into the covered socket. With the
polymer in a non-tacky, but moldable stage of cure the ramus of the
mandible is repositioned and compressed into the socket for use in
molding the polymer as it continues to cure. As an alternative to
the use of minimally invasive means, each of these processes can be
performed using invasive surgical procedures, given the unique
qualities of the biomaterial.
Biomaterial Compositions
[0111] Applicants have discovered that one or all of the improved
properties set forth above can be achieved without detrimental
effect on other properties of the composition, either before,
during or following delivery and cure. The term "detrimental
effect", as used herein, refers to an effect on one or more other
properties that would render the composition unsuitable for its
intended use.
[0112] The musculoskeletal system, and more often its articulating
joints, are subject to injury caused by traumatic events or
diseases such as osteoarthritis and rheumatoid arthritis. Inherent
lubricity of joint's connective tissue, the cartilage, is affected.
The non-functioning cartilage causes, in turn, abnormal wear and
tear of both the connective tissue and bones. This process often
results in progressive, crippling pain. With in vivo tissue repair
via cell transplant and implantation in its infancy and total joint
athroplasty not always a practical solution, the need for
alternative treatment is quite obvious.
[0113] We have developed methodology which utilizes minimally
invasive athroscopic surgery to remove damaged cartilage followed
with application of liquid, in situ cured polymer to resurface the
tibial plateau of the knee joint. Two component PTMO
polyether-based polyurethane system has been chosen as the polymer
of choice. The MDI quasi prepolymer approach was selected to
liquefy the MDI isocyanate and controlled cross-linking in the hard
segment was utilized to achieve needed biodurability. In order to
manage "isothermal curing environment" of in vivo application,
delayed action catalysis with Tin/amine synergism was used. The
system was mixed and delivered to the athroscopically prepared site
via delivery device with static mixer/cannula combination, then
shaped and cured to its desired shape.
[0114] Physical-mechanical properties were determined according to
ASTM Methods and in vitro biodurability via accelerated
oxidative/hydrolytic degradation. In vivo function in the knee of
ovine (sheep) model were determined at 3, 12, 26 and 52 weeks of
implantation.
[0115] Physical-mechanical properties of the polyurethane system
can be highlighted by Hardness of 70-75A Shore, Tensile Strength of
60-75 Mpa, Ultimate Elongation of 350-450% and Die "C" Tear of
28-44 kN/M. Compression Moduli were determined at 4.48 kN load and
indicated deformation of 20-40%. Finally, compression fatigue, at
2.2 kN force indicated that 1.5.times.10.sup.7 cycles, at 10
cycles/sec, did not alter compression moduli of the polymer.
[0116] The system does not generate cytotoxic by-products when
cured in n-saline, at 23.degree.C., between 10 seconds and 24 days
testing period. Finally, necropsy at time of sacrifice of the
animal models revealed essential integrity of the implant and no
adverse tissue reaction was detected by histopathology.
Encouragingly, signs of cartilage regeneration were detected at
tissue/polyurethane interface. We can conclude that in situ cured
polyurethanes, combined with minimally invasive athroscopic
procedure represent novel, promising way to resurface damaged body
joints.
[0117] Concepts governing in vivo resurfacing of damaged articular
cartilage by in situ curable polymers are outlined above. Briefly
reviewed, a pre-polymer is delivered to the "repair site" by
athroscopic procedure, shaped and polymerized in situ to restore
and augment cushioning and lubricating functions of the cartilage.
Material selection, its mechanical properties, biodurability and in
vivo performance are subject of this paper.
[0118] The polymer system one must have certain key
characteristics: (1) it should be amenable to microphase separation
and domain formation to mimic the cartilage; (2) the system must be
liquid at delivery; (3) polymerization kinetics must be fast and
fully controllable; (4) no toxic or otherwise harmful by-products
can be released; (5) resultant polymer must have broad range of
mechanical properties, excellent loan bearing, fatigue and wear
resistance; (6) the system should be amenable to form microcellular
structure; (7) lastly, the polymer must biodurable. Polyurethanes
could be the chosen one.
[0119] Although aromatic polyurethanes based on polycarbonate
polyols are considered most resistant to stress- and
oxidation-driven Environmental Stress Cracking, we have selected
PTMO-based polyols recognized for their superb hydrolytic
resistance. A two component system with MDI-quasi-prepolymer
component "A" and OH-terminated intermediates as component "B" was
used. Blend of polyols was the choice to keep their melting
temperature close to the ambient. The "delayed action" fast curing
kinetics was achieved with Tin compound/tertiary amine based
catalyst system. Gel times of 10-40 sec. with predominant cure of
2-5 min. are required to mix, deliver, cure and shape the
polyurethane. Such short times are preferred to lower total curing
exotherm but require chemical cross-linking to augment virtual ones
formed by hard segment domains. This is accomplished, in such soft
materials with target harness of 60-80 Shore A, by the blend of
linear and polyfinctional chain extenders. This also generates
unique tensile and compression behavior similar to those of
x-linked rubber and highlighted by Tensile strength of 60-75 Mpa,
elongation of more than 300% and Compression fatigue in excess of
20 million cycles at 2.2 kN force. Finally, two-plus years of in
vivo biodurability is expected as determined by hydrogen
peroxide/cobalt chloride testing.
[0120] To enhance cushioning function and to promote tissue
integration, microcellular structure can be achieved by controlled
nucleation of N.sub.2 gas. We can conclude that polyurethanes are
ideally suited for in vivo resurfacing of articular cartilage.
[0121] Natural cartilage is a non-vascular structure found in
various parts of the body. Articular cartilage tends to exist as a
fine granular matrix forming a thin incrustation on the surfaces of
joints. The natural elasticity of articular cartilage enables it to
break the force of concussions, while its smoothness affords ease
and freedom of movement. In one embodiment a preferred composition
is intended to mimic many of the physical, chemical and/or
mechanical characteristics of natural cartilage. In an another
preferred embodiment, a composition of this invention provides a
useful implant in the form of a catheter, e.g., a stent, graft or
shunt, by the use of a mold apparatus as described above. In such
an embodiment the cured composition provides a number of
characteristics, including biocompatability, strength, and the
like.
[0122] Compositions can be provided as one component systems, or as
two or more component systems that can be mixed (or partially
mixed) prior to or during delivery, or at the site of repair.
Generally such compositions are flowable in their uncured form,
meaning they are of sufficient viscosity to allow their delivery
through a cannula of on the order of about 2 mm to about 6 mm inner
diameter, and preferably of about 3 mm to about 5 mm inner
diameter. Such compositions are also curable, to enable them to be
polymerized or otherwise modified, in situ, during delivery and/or
at the tissue site, in order to undergo a phase or chemical change
sufficient to retain a desired position and configuration.
[0123] When cured, suitable materials can be homogeneous, providing
the same physicochemical properties throughout, or they can be
heterogeneous and exhibit varying features or properties. An
example of a suitable homogeneous composition, as presently used
for knee joint repair, is described below. An example of a
heterogeneous composition, e.g., for use as an intervertebral disc
replacement, is a composition that mimics the natural disc by
providing a more rigid outer envelope (akin to the annulus) and an
more liquid interior core (akin to the nucleus). Such heterogeneous
compositions can be prepared by the use of a single composition,
e.g., by employing varying states of cure and/or by the use of a
plurality of compositions, including varying compositions of the
same ingredients used to form the composition.
[0124] Suitable compositions for use in the present invention are
those polymeric materials that provide an optimal combination of
properties relating to their manufacture, application, and in vivo
use. In the uncured state, such properties include processability,
and the ability to be safely sterilized and stored. In the course
of applying such compositions, suitable materials exhibit an
optimal combination of such properties as flowability, moldability,
and in vivo curability. In the cured state, suitable compositions
exhibit an optimal combination of such properties as cured strength
(e.g., tensile and compressive), softness/stiffness ratio,
biocompatability and biostability.
[0125] When cured, the compositions demonstrate an optimal
combination of properties, particularly in terms of their
conformational stability and retention of physical shape,
dissolution stability, biocompatability, and physical performance,
as well as physical properties such as density and surface
roughness, and mechanical properties such as load-bearing strength,
tensile strength, shear strength, shear fatigue, impact absorption,
wear characteristics, and surface abrasion. Such performance can be
evaluated using procedures commonly accepted for the evaluation of
natural tissue and joints, as well as the evaluation of materials
and polymers in general. In particular, a preferred composition, in
its cured form, exhibits mechanical properties that approximate or
exceed those of the natural tissue it is intended to provide or
replace.
[0126] Preferred components of compositions, and compositions
themselves, are also stable under conditions used for
sterilization, and additionally are stable on storage and in the
course of delivery. They are also capable of flowing through a
delivery cannula to an in vivo location, and being cured in situ,
as by chemical catalysis, by exposure to an energy source such as
ultraviolet light, or by chemical reaction producing exotherm.
Thereafter the cured composition is suitably amenable to shaping
and contouring, by the use of conventional or custom designed
arthroscopic tools or instruments. Over the course of its use in
the body the cured, contoured composition exhibits physiological,
physical-chemical and mechanical properties suitable for use in
extended in vivo applications.
[0127] Components A "polymer system", as used herein refers to the
component or components used to prepare a polymeric composition of
the present invention. In a preferred embodiment, a polymer system
comprises the components necessary to form two parts: Part I being
an isocyanate-functional polyurethane pre-polymer (optionally
referred to as an "isocyanate quasi-polymer"). The quasi-polymer of
Part I typically includes a polyol component in combination with a
hydrophobic additive component and an excess of an isocyanate
component. Part II of the two component system can include one
long-chain polyols, chain extenders and/or cross-linkers, together
with other ingredients (e.g., catalysts, stabilizers, placticizers,
antioxidants, dyes and the like). Such adjuvants or ingredients can
be added to or combined with any other component thereof either
prior to or at the time of mixing, delivery, and/or curing.
[0128] In a particularly preferred embodiment, a polymer system of
this invention is provided as a plurality of component parts and
employs one or more catalysts. The component parts, including
catalyst, can be mixed to initiate cure, and then delivered, set
and fully cured under conditions (e.g., time and exotherm)
sufficient for its desired purpose. Upon the completion of cure,
the resultant composition provides an optimal combination of
properties for use in repairing or replacing injured or damaged
tissue. In the course of curing, a suitable composition provides a
bulk exotherm (within samples sizes suitable for in vivo use) of
between about 100 degrees C. and about 140 degrees C., and
preferably between about 110 degrees C. and about 130 degrees C.,
and a surface exotherm of between about 50 degrees C. and about 80
degrees C., and preferably between about 60 degrees C. and about 70
degrees C.
[0129] In order to obtain a cured composition having desired
physical-chemical, mechanical and physiological properties, a
significant factor in the choice of appropriate isocyanate, polyol
and chain extender/cross linker are their chemical composition and
molecular weight. A composition of this invention can be expressed
in terms of both: (1) the free isocyanate number ("FNCO") (also
known as the isocyanate equivalent), which can be defined as the
average molecular weight of the isocyanate divided by the number of
isocyanate functional groups, and (2) the average hydroxyl number
(also know as hydroxyl equivalent weight), which can be defined as
the average molecular weight of the polyol(s) divided by the
average number of reactive hydroxyl groups per mole of
polyol(s).
[0130] The isocyanate component can be provided in any suitable
form, examples of which include 2,4'-diphenylmethane diisocyanate,
4,4'-diphenylmethane diisocyanate, and mixtures or combinations of
these isomers, optionally together with small quantities of
2,2'-diphenylmethane diisocyanate (typical of commercially
available diphenylmethane diisocyanates). Other examples include
aromatic polyisocyanates and their mixtures or combinations, such
as are derived from phosgenation of the condensation product of
aniline and formaldehyde. It is suitable to use an isocyanate that
has low volatility, such as diphenylmethane diisocyanate, rather
than more volatile materials such as toluene diisocyanate. An
example of a particularly suitable isocyanate component is the
4,4'-diphenylmethane diisocyanate ("MDI"), preferably provided in
liquid form as a combination of 2,2'-, 2,4'- and 4,4'- isomers of
MDI.
[0131] For a suitable composition, the stoichiometery between Parts
I (quasi prepolymer) and II (curative component), expressed in
terms of the NCO:OH ratio of the isocyanate pre-polymer (Part I)
and the polyol components (Part II) is preferably within the range
of about 0.8 to 1 to about 1.2 to 1, and more preferably between
about 0.9 to 1 to about 1.1 to 1. It has been found that NCO:OH
ratios of less than about 0.8 to 1 tend to provide less than
desired cure kinetics or physical-mechanical properties upon cure.
Those ratios greater than about 1.1 to 1, in turn, tend to increase
the potential for cytotoxicity or for adverse tissue reaction
characterized by over crosslinking via internal allophanate or
biuret links, generated by an excess of FNCO groups.
[0132] The polyol component can be provided in any suitable form as
well. As used herein, the term "polyol" includes virtually any
functional compound having active hydrogens in accordance with the
well-known Zerevitinov test, as described for instance in Chemistry
of Organic Compounds by Carl R. Noller, Chapter 6, pp. 121-122
(157), the disclosure of which is incorporated herein by reference.
Thus, for example, amine terminated polyethers and polyolefins,
thiols, polyimines, and polyamines can also be used as polyols in
the present invention. In such instances, the NCO:active hydrogen
ratio of the isocyanate to the active hydrogen compound will
preferably fall within the same ranges as disclosed herein for the
NCO:OH ratios.
[0133] Suitable polyols for use in preparing a composition of this
invention include polyalkylene ethers derived from the condensation
of alkylene oxides (e.g., ethylene oxide, propylene oxide, and
blends thereof), as well as tetrahydrofuran based
polytetramethylene ether glycols, polycaprolactone polyols,
polycarbonate polyols and polyester polyols. Examples of suitable
polyols include polytetrahydrofuran polyol ("PTHF", also known as
polytetramethylene oxide ("PTMO") or polytetramethylene ether
glycol ("PTMEG").
[0134] Preferably, the polyol component can be provided in the form
of a blend of two or more different molecular weights selected from
the commercially available group consisting of 250, 650, 1000,
1400, 2000, and 2900. Materials having different molecular weights
can be blended, e.g., using between 10:1 and 1:10 equivalent
weights of a lower and higher molecular weight component (e.g., 250
and 1000 MW components), respectively, and preferably between about
2:1 and about 1:2 equivalent weights. The optimal combination of
components, as well as the absolute and relative proportions
thereof, are selected to provide a polymer system that, upon mixing
an/or heating, is sufficiently "flowable" under ambient or other
selected controlled conditions (e.g., temperature) to permit it to
be sterilized, mixed, delivered, and cured, e.g., using minimally
invasive means, to provide the properties desired for in vivo
applications as described herein.
[0135] A preferred polymer system of this invention also includes
the use of one or more chain extenders. Suitable chain extenders
for use in the present invention provide an optimal combination of
such properties as hard segment molecular weight and molecular
weight distribution, phase separation and domain formation, virtual
cross-linking by hard segment domains. In cases in which more than
two functional extenders are used, their combination also provides
an optimal or desire level of chemical crosslinking between both
hard segment chains and hard and soft segment chains.
[0136] An example of a particularly preferred chain extender is a
combination of a linear (e.g., two-functional) chain extender, such
as 1,4-butanediol ("BDO"), together with a cross-linking (e.g.,
tri- or higher-functional) chain extender such as trimethylol
propane ("TMP"). Such chain extenders can be prepared in any
suitable combination to produce a unique degree of cross-linking,
predominantly in the hard segment domains but also crossing the
phase boundaries.
[0137] Additional cross-linking in the hard segment augments the
virtual cross-links generated by the hard segment domains and
provides higher cross-link density and efficiency, resulting in the
reinforcement of non cross-linked segments. This can be
particularly useful in relatively soft polyurethanes, such as those
suitable for the repair of damaged cartilage. Reinforcement by
virtual cross-links alone may not generate sufficient strength for
in vivo performance in certain applications. Additional
cross-linking from the soft segment, potentially generated by use
of higher functional polyols can be used to provide stiffer and
less elastomeric materials. In this manner a balancing of hard and
soft segments, and their relative contributions to overall
properties can be achieved.
[0138] Additionally, a polymer system of the present invention
preferably contains one or more, and more preferably two or more,
biocompatible catalysts that can assist in controlling the curing
process, including the following periods: (1) the induction period,
(2) the setting period, and finally, (3) the final cure of the
biomaterial. Together these three periods, including their absolute
and relative lengths, and the rate of acceleration or cure within
each period, determine the cure kinetics or profile.
[0139] The word "induction", and inflections thereof, when used in
this respect refers to the time period between mixing or activation
of one or more polymer components (under conditions suitable to
begin the curing process), and the onset of gelation. In a method
of the present invention, this period generally corresponds with
the delivery of the biomaterial to the site of ultimate use. The
induction period is characterized by infinitesimal or limited
increase in viscosity of reacting mixture and relatively flat
exotherm profile. Generally, a biomaterial of this invention is
simultaneously mixed just prior to actual delivery into the joint
site, providing the surgeon with sufficient time to add and
position material (e.g., into anchor points) before gelation causes
the material to become less easily workable. Thereafter, the
surgeon can leave the material in place as it sets, e.g., for on
the order of three to twenty minutes, before placing instruments
back into the site to finish sculpting the implant, or performing
other desired steps such as positioning the femoral condyles to
shape the implant.
[0140] The term "set time" (or gel time), as used herein, is
determined from the initial mixing of components, and refers to the
time needed for a mixed and delivered system to set to the point
where it can be shaped. This period is characterized by a rapid
rise in the slope of the reaction exotherm at the end of the
period. By the end of this period, the surface of the gelled
biomaterial is preferably tack free and will allow shaping, e.g.,
by positioning of the condyles. The "cure time", as used herein, is
determined from the initial mixing, and refers to the total time
needed to mix, shape and fully cure the biomaterial to the desired
extent under the conditions used. Preferred polymer systems of this
invention preferably provide an induction period that ends within
about thirty seconds to two minutes following mixing of the
components, followed by a set time of about 3 to about 15 minutes
following mixing.
[0141] During the curing process (including both setting and
completion of cure) the polymer system preferably exhibits an
exotherm compatible for its intended use, e.g., preferably an
exotherm of less than about 70 to about 90.degree.C., and more
preferably less than about 80.degree.C. Given the present
description, those skilled in the art will appreciate the manner in
which the polymer system can be adjusted in a variety of ways to
obtain suitable exotherm, during setting and cure, e.g., by the use
of temperature dependent synergistic catalysis. Catalysts suitable
for use in compositions of the present invention provide an optimal
combination of such properties as set time, cure time, and in turn,
viscosity (and flowability) of the curing polymer system.
[0142] In a particularly preferred embodiment, the selection of
catalyst and other ingredients provides a cure profile that
exhibits both synergistic and "delayed action" kinetics, in which
induction of cure begins immediately upon mixing the polymer
components, and is relatively "flat" during the induction period,
without significant increase of viscosity of reaction mixture. This
period permits delivery of the "flowable" polymer to the tissue
injury site, and is followed by a setting period characterized by
variable increase in slope (in a plot of temperature vs. time) that
is designed to quickly drive the curing process to completion, and
in turn, to quickly provide a set polymer that is sufficiently
strong and tack-free to permit final shaping.
[0143] Examples of suitable catalyts include tin compounds (such as
tin esters, tin alkylesters, and tin mercaptides), amines, such as
tertiary amines and the like. An example of a suitable catalyst
system is a combination of a tin catalyst (e.g., "Cotin 222",
available under the trademark "Cotin 222"from Cascam, Company,
Bayonne N.J.) and a tertiary amine (e.g., DABCO(TEDA), a
triethylene diamine catalyst available from Air Products,
Allentown, Pa. These components can be used in any suitable ratio,
e.g., between about 1:1 parts and about 1:5 parts of the tin
catalyst and the diamine, respectively.
[0144] Other ingredients can be used as well, including different
amine-based catalysts available to those in the art. Examples of
optional ingredients include antioxidants, such as vitamin E, which
can be used as a biocompatible antioxidant and mediator of
macrophage attack designed to destroy the implant in vivo.
[0145] Other suitable ingredients include dyes, such as "Green GLS
Dye" (available from Clarian Corp., Charlotte, N.C.) that can be
added (e.g., at a concentration of about 0.01% to about 0.05%, by
weight) to facilitate the ability to visualize the polymer in the
course of delivery to the "repair" site. Preferred dyes are stable
to change in the course of sterilization, e.g., by irradiation such
as gamma or Electron-beam.
[0146] Optionally, inorganic fillers, such as calcium carbonate,
titanium dioxide or barium sulfate can be added as well, in about
0.5 to about 20 percent (by weight) to affect the viscosity and
thixotropic properties of the resultant mixture, to modify or
increase the load bearing ability of the polymer and/or to render
the implanted biomaterial radiopaque.
[0147] Preparation and Delivery The composition of the present
invention can be delivered and cured within the body, preferably by
minimally invasive means. In one preferred embodiment, the
composition is used to resurface or repair a joint, such as a knee
or intervertebral disc. In another preferred embodiment, the
composition is used to form an implant in situ, e.g., in the form
of a catheter such as a stent, graft, or shunt.
[0148] Ingredients such as those provided herein can be combined in
any suitable manner to provide a composition capable of being
delivered to the injury site, preferably via minimally invasive
means. In a preferred embodiment, the composition is provided as a
system having a plurality of parts, e.g., a two-part system,
wherein the two parts are capable of being separately prepared,
sterilized, and packaged, such that the parts can be mixed in the
operating room and at the time of use in order to initiate the
curing process.
[0149] Compositions provided as a plurality of components, e.g., a
two-part polyurethane system, can be mixed at the time of use using
suitable mixing techniques, such as those commonly used for the
delivery of two-part adhesive formulations. A suitable mixing
device involves, for instance, a static mixer having a hollow tube
having a segmented, helical vein running through its lumen. A
two-part polyurethane system can be mixed by forcing the respective
components through the lumen, under pressure. In addition, any
mechanically driven mixing device or impingement mixing device are
suitable to accomplish the mixing of a plurality of components.
[0150] In a further embodiment, the static mixer can be used in a
system having an application cannula, an application tip, and a
cartridge having two or more chambers, each containing a separate
component of the composition system. A hand-powered, pneumatically,
or electrically controlled extrusion gun can be used to extrude or
eject the components through, for example, the static mixer, in
order to completely mix them and thereby begin the process of
curing. The composition system then flows through the cannula and
to the joint site or surface through the application tip. The
length, diameter, and vein design of the mixing element can be
varied as necessary to achieve the desired mixing efficiency.
[0151] The composition of the present invention can be delivered to
a site within the body, and there cured, preferably using minimally
invasive means, in order to repair (e.g., reconstruct or resurface)
tissue such as cartilage, and particularly cartilage associated
with diarthroidal and amphiarthroidal joints. Optionally, the
composition can be delivered and cured within an implanted mold
device. Using minimally invasive means a composition can be
delivered to a site within the body, e.g., to a mold or a site of
damaged or diseased cartilage, to be cured in situ in order to
provide an implant or repair the cartilage without undue surgical
trauma.
[0152] In other aspects, the invention provides compositions,
including polymer systems, useful for performing such a method, as
well as methods of preparing and using such compositions. In yet
further aspects, the invention provides a joint, e.g., a
diarthroidal or amphiarthroidal joint, having interposed therein a
composition that has been delivered and cured in situ.
[0153] Properties Compositions of the present invention provide
improvement in one or more of the following properties as compared
to those previously known, without detrimental effect on other
desirable properties described herein.
[0154] In a particularly preferred embodiment, Applicants have
discovered a composition that provides significantly improved
hardness and strength during stage (c) identified above, while also
providing improved cure kinetics during stage (b), all without
undue effect on other desirable properties. In its fully cured
state, for instance, a suitable composition of the present
invention provides a hardness of about 60 Shore to about 95 Shore,
as determined by ASTM Test Method D2240 set forth herein.
Optionally, and preferably in addition to such improved hardness,
the fully cured composition provides improved tensile strength as
well, as determined by ASTM Test Method D412 herein. For instance,
a preferred composition of this invention provides a tensile
strength (measured in the dry state) of about 6,000 psi to about
10,000 psi. The composition provides a "wet" tensile strength
(e.g., as determined after soaking the sample in saline for one
week) of about 3,000 psi to about 5,000 psi. As a further optional
feature, a preferred composition of this invention provides a
biphasic cure pattern, as depicted and described with respect to
FIG. 1 herein.
[0155] Optionally, or preferably in addition to improved hardness,
a preferred fully cured composition of this invention provides a
tensile strength of about 6,000 psi to about 10,000 psi, as
determined by ASTM Test Method D412 herein.
[0156] Accordingly, in a preferred embodiment, the present
invention provides a curable polyurethane composition comprising a
plurality of parts capable of being sterilized, stably stored, and
mixed at the time of use in order to provide a flowable composition
and to initiate cure, the parts including: (1) a quasi-prepolymer
component comprising the reaction product of one or more polyether
polyols, one or more isocyanates, and one or more reactive
hydrophobic additives, and (2) a curative component comprising one
or more polyether polyols, one or more chain extenders, and one or
more catalysts.
[0157] More preferred is a composition as described above wherein
the reactive hydrophobic additive comprises an hydroxyl- or
amine-terminated polymer or copolymer selected from the group
consisting of poybutadiene, polyisobutylene, silicone,
polyisoprene, copolymers of butadiene with acryolnitrile,
copolymers of butadiene with styrene, copolymers of isoprene with
acrylonitrile, copolymers of isoprene with styrene, and mixtures
thereof, and particularly preferred is a composition wherein the
additive comprises hydroxyl-terminated polybutadiene. Within such a
composition, the hydroxyl-terminated polybutadiene can be present
at a concentration of between about 5% and about 20%, by weight,
based on the weight of the composition, and more preferably between
about 8% and about 15% by weight.
[0158] Also preferred is a composition as described herein wherein
the polyether component is selected from the group consisting of
linear or branched polyols with polyether backbones of
polyoxyethylene, polyoxypropylene, and polyoxytetramethylene, and
copolymers thereof, e.g., wherein the polyether component is
present in the prepolymer component at a concentration of between
about 2% and about 10% by weight, and is present in the curative
component at a final concentration of between about 25% and 45%,
based on the weight of the composition. An example of such a
composition is one in which the polyether component comprises
polytetramethylene oxide having a molecular weight in the range of
250 to 1000.
[0159] Further preferred is a composition which the isocyanate
component comprises an aromatic isocyanate selected from the group
consisting of 2,2'-, 2,4'-, and 4,4'-diphenylmethanediisocyanate,
and combinations thereof, preferably where the isocyanate is
present in excess in the prepolymer component, at a concentration
of between about 30% and about 50% by weight, based on the weight
of the composition.
[0160] In another aspect, the invention provides a curable
polyurethane composition comprising a plurality of parts capable of
being sterilized, stably stored, and mixed at the time of use in
order to provide a flowable composition and to initiate cure, the
parts including:
[0161] (1) a quasi-prepolymer component comprising the reaction
product of
[0162] (a) one or more polyether polyols selected from the group
consisting of linear or branched polyols with polyether backbones
of polyoxyethylene, polyoxypropylene, and polyoxytetramethylene,
and copolymers thereof,
[0163] (b) one or more isocyanates selected from the group
consisting of 2,2'- , 2,4'-, a and 4,4'-diphenylmethanediisocyanate
(MDI), and combinations thereof, and
[0164] (c) one or more reactive hydrophobic additives comprising
hydroxyl- or amine-terminated compounds selected from the group
consisting of poybutadiene, polyisobutylene, silicones,
polyisoprene, copolymers of butadiene with acryolnitrile,
copolymers of butadiene with styrene, copolymers of isoprene with
acrylonitrile, copolymers of isoprene with styrene, and mixtures
thereof, and
[0165] (2) a curative component comprising
[0166] (a) one or more polyether polyols as defined in part
(1)(a),
[0167] (b) a combination of linear and branched chain extenders,
and
[0168] (c) one or more catalysts.
[0169] Preferably the catalysts, in combination with the remaining
components, are sufficient to permit the composition to cure upon
mixing at physiological temperature with a cure profile that
comprises sequentially an onset period, a gelation period, and a
complete cure period.
[0170] In yet another aspect, the invention provides a cured
polyurethane implant suitable for extended use in vivo, the implant
being formed as the reaction product of a composition that
comprises: (1) a quasi-prepolymer component comprising the reaction
product of one or more polyether polyols, one or more isocyanates,
and one or more reactive hydrophobic additives, and (2) a curative
component comprising one or more polyether polyols, one or more
chain extenders, and one or more catalysts. Such an implant
exhibits improved Shore Hardness and tensile strength, as compared
to an implant prepared from a comparable composition lacking
hydrophobic additives, e.g., a Shore hardness of between about 60
and about 95 Shore, as determined by ASTM Test Method D2240, and a
dry tensile strength of between about 6000 psi and about 10,000
psi, as determined by ASTM Test Method D412. The invention also
provides such an implant according positioned in permanent or
temporary contact with ajoint surface in vivo, and preferably
positioned in permanent contact with the surface of subchrondral
bone in the knee joint.
[0171] The invention also provides a kit comprising a plurality of
sterile, flowable parts capable of being mixed at the time of use
in order to provide a flowable composition and to initiate cure,
the parts including: (1) a quasi-prepolymer component comprising
the reaction product of one or more polyether polyols, one or more
isocyanates, and one or more reactive hydrophobic additives, and
(2) a curative component comprising one or more polyether polyols,
one or more chain extenders, and one or more catalysts. Preferably,
the kit further comprises a delivery device for use in mixing the
quasi-prepolymer component and curative component, and delivering
the mixture to a tissue site using minimally invasive means.
[0172] Common polymeric materials for use in medical devices
include, for example, polyvinyl chlorides, polyethylenes, stryrenic
resins, polypropylene, thermoplastic polyesters, thermoplastic
elastomers, polycarbonates, acrylonitrile-butadiene-styrene ("ABS")
resins, acrylics, polyurethanes, nylons, styrene acrylonitriles,
and cellulosics. See, for example, "Guide to Medical Plastics",
pages 41-78 in Medical Device & Diagnostic Industry, April,
1994, the disclosure of which is incorporated herein by
reference.
[0173] Suitable matrix materials (i.e., biomaterials) for use in
the present invention are those polymeric materials that provide an
optimal combination of properties relating to their manufacture,
application, and in vivo use. In the uncured state, such properties
include processability and the ability to be stably sterilized and
stored. In the course of applying such material, such properties
include hydrogel compatibility and capacity, flowability, and in
vivo curability. In the cured state, such properties include
moldability, cured strength (e.g., tensile and compressive),
elongation to break, and biocompatability. Examples of suitable
matrix materials include, but are not limited to, silicone polymers
and polyurethane polymers.
[0174] In a preferred embodiment, the biomaterial matrix is formed
of a silicone polymer, i.e., polymer containing a repeating
silicon-oxygen backbone together with organic R groups attached to
a significant portion of the silicon atoms by silicon-carbon bonds.
See generally, "Silicones", pages 1048-1059 in Concise Encyclopedia
of Polymer Science and Engineering, Eds. Mark et al., Wiley and
Sons, 1990, the disclosure of which is incorporated herein by
reference.
[0175] Silicone polymers are commercially available in at least
three general classes, namely as homopolymers, silicone random
polymers, and silicone-organic (block) copolymers. Homopolymers in
the form of polydimethyl siloxanes are preferred, and constitute
the largest volume of homopolymers produced today.
[0176] In an alternative preferred embodiment, the biomaterial
matrix is formed of a polyurethane polymer. Polyurethanes, e.g,
thermoplastic polyurethanes ("TPU"), are typically prepared using
three reactants: an isocyanate, a long-chain macrodiol, and a
short-chain diol extender. The isocyanate and long-chain diol form
a "soft" segment, while the isocyanate and short-chain diol form a
"hard" segment. It is the interaction of soft and hard segments
that determines and provide the polymer with rubber-like
properties.
[0177] During melt processing, the polyurethane chains are linear
and assume the configuration into which they are formed, such as by
injection molding, or in the case of the present invention, by
arthroscopic application. On cooling, the hard segments form
ordered domains held together by hydrogen bonding. These domains
act as cross-links to the linear chains, making the material
similar to a cross-linked rubber.
[0178] Those skilled in the art, in view of the present invention,
will appreciate the manner in which the choice of isocyanate,
macrodiol, and chain extender can be varied to achieve a wide
diversity of properties. Preferred TPU's for medical use are
presently based on the use of a diisocyanate such as
diphenylmethane diisocyanate ("MDI"), a glycol such as
polytetramethylene ether glycol, and a diol such as
1,4-butanediol.
[0179] Natural cartilage is a non-vascular structure found in
various parts of the body. The natural elasticity of articular
cartilage enables it to break the force of concussions, while its
smoothness affords ease and freedom of movement. In terms of
thickness, cartilage tends to take on the shape of the articular
surface on which it lies.
[0180] Preferred biomaterials, therefore, are intended to mimic
many of the physical-chemical characteristics of natural cartilage.
Biomaterials can be provided as one component systems, or as two or
more component systems that can be mixed prior to or during
delivery, or at the site of repair. Generally such biomaterials are
flowable in their uncured form, meaning they are of sufficient
viscosity to allow their delivery through a cannula of on the order
of about 1 mm to about 6 mm inner diameter, and preferably of about
2 mm to about 3 mm inner diameter. Such biomaterials are also
curable, meaning that they can be cured or otherwise modified, in
situ, at the tissue site, in order to undergo a phase or chemical
change sufficient to retain a desired position and
configuration.
[0181] When cured, preferred materials can be homogeneous (i.e.,
providing the same chemical-physical parameters throughout), or
they can be heterogeneous. An example of a heterogeneous
biomaterial for use as a disc replacement is a biomaterial that
mimics the natural disc by providing a more rigid outer envelope
(akin to the annulus) and a more liquid (e.g, cushioning or softer)
interior core (akin to the nucleus). In an alternative embodiment,
biomaterials can be used that provide implants having varying
regions of varying or different physical-chemical properties. With
disc replacement, for instance, biomaterials can be used to provide
a more rigid, annulus-like outer region, and a more fluid,
nucleus-like core. Such di-or higher phasic cured materials can be
prepared by the use of a single biomaterial, e.g., one that
undergoes varying states of cure, or a plurality of
biomaterials.
[0182] Common polymeric materials for use in medical devices
include, for example, polyvinyl chlorides, polyethylenes, styrenic
resins, polypropylene, thermoplastic polyesters, thermoplastic
elastomers, polycarbonates, acrylonitrile-butadiene-styrene ("ABS")
resins, acrylics, polyurethanes, nylons, styrene acrylonitriles,
and cellulosics. See, for example, "Guide to Medical Plastics",
pages 41-78 in Medical Device & Diagnostic Industry, April,
1994, the disclosure of which is incorporated herein by
reference.
[0183] Suitable biomaterials for use in the present invention are
those polymeric materials that provide an optimal combination of
properties relating to their manufacture, application, and in vivo
use. In the uncured state, such properties include processability,
and the ability to be stably sterilized and stored. In the course
of applying such material, such properties as flowability,
moldability, and in vivo curability. In the cured state, such
properties include cured strength (e.g., tensile and compressive),
stiffness, biocompatability and biostability. Examples of suitable
biomaterials include, but are not limited to, polyurethane
polymers.
[0184] In a preferred embodiment, the biomaterial comprises a
polyurethane polymer. Polyurethanes, e.g, thermoplastic
polyurethanes ("TPU"), are typically prepared using three
reactants: an isocyanate, a long-chain macrodiol, and a short-chain
diol extender. The isocyanate and long-chain diol form a "soft"
segment, while the isocyanate and short-chain diol form a "hard"
segment. The hard segments form ordered domains held together by
hydrogen bonding. These domains act as cross-links to the linear
chains, making the material similar to a cross-linked rubber. It is
the interaction of soft and hard segments that determines and
provides the polymer with rubber-like properties.
[0185] Those skilled in the art, in view of the present invention,
will appreciate the manner in which the choice of isocyanate,
macrodiol, and chain extender can be varied to achieve a wide array
of properties. Preferred TPU's for medical use are presently based
on the use of a diisocyanate such as diphenylmethane diisocyanate
("MDI"), a glycol such as polytetramethylene ether glycol, and a
diol such as 1,4-butanediol.
[0186] Biomaterials of the present invention can also include other
optional adjuvants and additives, such as stabilizers, fillers,
antioxidants, catalysts, plasticizers, pigments, and lubricants, to
the extent such optional ingredients do not diminish the utility of
the composition for its intended purpose.
[0187] When cured, the biomaterials demonstrate an optimal
combination of physical/chemical properties, particularly in terms
of their conformational stability, dissolution stability,
biocompatability, and physical performance, e.g., physical
properties such as density, thickness, and surface roughness, and
mechanical properties such as load-bearing strength, tensile
strength, shear strength, fatigue, impact absorption, wear
characteristics, and surface abrasion. Such performance can be
evaluated using procedures commonly accepted for the evaluation of
natural tissue and joints, as well as the evaluation of
biomaterials.
[0188] In particular, preferred biomaterials, in the cured form,
exhibit mechanical properties that approximate those of the natural
tissue that they are intended to replace. For instance, for load
bearing applications, preferred cured composites exhibit a load
bearing strength of between about 50 and about 500 psi (pounds per
square inch), preferably between about 100 and about 300 psi, and
more preferably between about 100 and 200 psi. Such composites also
exhibit a shear stress of between about 10 and 100 psi, and
preferably between about 30 and 50 psi, as such units are typically
determined in the evaluation of natural tissue and joints. Such
composites also exhibit a tensile strength of between about 3500
and about 6000 psi, and preferably between about 4000 and about
5000 psi, using test methods generally available to those skilled
in the art, for instance using an "Instron" tensile tester.
[0189] Preferred biomaterials are also stable under conditions used
for sterilization, and additionally are stable on storage and in
the course of delivery. They are also capable of flowing through a
delivery cannula to an in vivo location, and being cured in situ,
as by exposure to an energy source such as ultraviolet light or by
chemical reaction. Thereafter the cured biomaterial is suitably
amenable to shaping and contouring, by the use of conventional or
custom designed arthroscopic tools or instruments. Over the course
of their use in the body the cured, contoured biomaterial exhibits
physical-chemical properties suitable for use in extended in vivo
applications.
[0190] In a preferred embodiment, the biomaterial is a polyurethane
provided as a two-part prepolymer system comprising a diisocyanate,
a polyalkylene oxide and low molecular diols as chain extenders.
The final polymer having a hard segment content of about 25 to
about 50% by weight, and preferably of about 30 to about 40% by
weight, based on the weight of the diisocyanate and chain extender.
Optionally, and preferably, one or more catalysts are incorporated
into one or more components of the biomaterial, in order to cure
the biomaterial in the physiological environment within a desired
length of time. Preferably, biomaterials of the present invention
are able to cure (i.e., to the point where distraction means can be
removed and/or other biomaterial added), within on the order of 5
minutes or less, and more preferably within on the order of 3
minutes or less.
[0191] Preferably, means are employed to improve the biostability,
i.e., the oxidative and/or hydrolytic stability, of the biomaterial
in vivo, thereby extending the life of the implant. See, for
instance, A. Takahara, et al., "Effect of Soft Segment Chemistry on
the Biostability of Segmented Polyurethanes. I. In vitro
Oxidation", J. Biomedical Materials Research, 25:341-356 (1991) and
A. Takahara, et al., "Effect of Soft Segment Chemistry on the
Biostability of Segmented Polyurethanes. II. In vitro Hydrolytic
Degradation and Lipid Sorption", J. Biomedical Materials Research,
26:801-818 (1992), the disclosures of both of which are
incorporated herein by reference.
[0192] Suitable means for improving biostability include the use of
an aliphatic macrodiol such as hydrogenated polybutadiene (HPDI).
By judicious choice of the corresponding diisocyanate (e.g., MDI)
and chain extender (e.g., ethylenediamine), those skilled in the
art will be able to achieve the desired packing density, or
crystallinity, of the hard segments, thereby improving the
hydrolytic stability of the cured polyurethane.
[0193] Biomaterials provided as a plurality of components, e.g., a
two-part polyurethane system, can be mixed at the time of use using
suitable mixing techniques, such as those commonly used for the
delivery of two-part adhesive formulations. A suitable mixing
device involves, for instance, a static mixer having a hollow tube
having a segmented, helical vein running through its lumen. A
two-part polyurethane system can be mixed by forcing the respective
components through the lumen, under pressure.
[0194] In a further embodiment, the static mixer can be used in a
system having an application cannula, an application tip, and a
cartridge having two or more chambers, each containing a separate
component of the biomaterial system. A hand-powered or electrically
controlled extrusion gun can be used to extrude the components
through the static mixer, in order to completely mix them and
thereby begin the process of curing. The biomaterial system then
flows through the cannula and to the joint site or surface through
the application tip. The length, diameter, and vein design of the
mixing element can be varied as necessary to achieve the desired
mixing efficiency.
[0195] Hydrogels suitable for use in composites of the present
invention are water-containing gels, i.e., polymers characterized
by hydrophilicity and insolubility in water. See, for instance,
"Hydrogels", pages 458-459 in Concise Encyclopedia of Polymer
Science and Engineering, Eds. Mark et al., Wiley and Sons, 1990,
the disclosure of which is incorporated herein by reference.
Although their use is optional in the present invention, the
inclusion of hydrogels is highly preferred since they tend to
contribute a number of desirable qualities. By virtue of their
hydrophilic, water-containing nature, hydrogels assist the cured
composite with load bearing capabilities of the cured composite.
They also tend to decrease frictional forces on the composite and
add thermal elasticity.
[0196] In a preferred embodiment, the hydrogel is a fine, powdery
synthetic hydrogel. Suitable hydrogels exhibit an optimal
combination of such properties as compatibility with the matrix
polymer of choice, and biocompatability.
[0197] Suitable hydrogels swell to an equilibrium volume in water,
but preserve their shape. Synthetic hydrogels suitable for use in
forming a composite of the present invention include those based on
methacrylic and acrylic esters, (meth)acrylamide hydrogels, and
those based on N-vinyl-2-pyrrolidinone.
[0198] Preferred hydrogels include those formed from monomeric
hydroxyalkyl acrylates and methacrylates, copolymerized with a
suitable cross-linking agent, such as ethylene dimethacrylate
("EDMA").
[0199] In a particularly preferred embodiment the matrix polymer is
a siloxane (i.e., silicone polymer), and preferably one selected
from the group consisting of alpha,
omega-dihydroxypoly(dimethylsiloxane) and poly(dimethylsiloxane)
with 0.2 mol % of vinylmethyl-siloxane units. Dispersed as the
hydrogel component in the preferred polymer is 15% to 30% (by
weight based on the weight of the uncured composite) of a lightly
cross-linked hydrogel aggregate. A preferred hydrogel aggregate is
formed by 2-hydroxyethyl methacrylate (HEMA) cross-linked by
ethylene dimethacrylate (EDMA) at a concentration of 2%-5% by
weight, based on the weight of the hydrogel.
[0200] Those skilled in the art will appreciate the manner in which
hydrogel/matrix combinations and concentrations can be altered
based on their intended application. For instance, a stiffer
composite with a low hydrogel concentration, e.g., .about.10% based
on the final weight of the composite, would be suitable for
intervertebral disc replacement.
[0201] Depending, for instance, on their intended application,
biomaterials will preferably contain a hydrogel phase at a
concentration of between about 15 and 50 weight percent, and
preferably between about 10 and about 50 weight percent, and
preferably between about 15 and about 30 weight percent, based on
the weight of the combination of matrix and hydrogel.
[0202] Composites of the present invention can also include other
optional adjuvants and additives, such as stabilizers, fillers,
antioxidants, catalysts, plasticizers, pigments, and lubricants, to
the extent such optional ingredients do not diminish the utility of
the composition for its intended purpose.
[0203] Cured polymer-hydrogel composites demonstrate an optimal
combination of physical/chemical properties, particularly in terms
of their conformational stability, dissolution stability,
biocompatability, and physical performance, e.g., physical
properties such as density, thickness, and surface roughness, and
mechanical properties such as load-bearing strength, tensile
strength, static shear strength, fatigue of the anchor points,
impact absorption, wear characteristics, and surface abrasion. Such
performance can be evaluated using procedures commonly accepted for
the evaluation of natural tissue and joints, as well as the
evaluation of biomaterials.
[0204] In particular, preferred composite materials, in the cured
form, exhibit mechanical properties approximating those of the
natural tissue that they are intended to replace. For instance,
preferred cured composites exhibit a load bearing strength of
between about 50 and about 200 psi (pounds per square inch), and
preferably between about 100 and about 150 psi. Such composites
also exhibit a shear stress of between about 10 and 100 psi, and
preferably between about 30 and 50 psi, as such units are typically
determined in the evaluation of natural tissue and joints.
[0205] Preferred biomaterials are also stable under conditions used
for sterilization, and additionally are stable on storage and in
the course of delivery. They are also capable of flowing through a
delivery cannula to an in vivo location, and being cured in situ,
as by exposure to an energy source such as ultraviolet light or by
chemical reaction. Thereafter the cured biomaterial is suitably
amenable to shaping and contouring, by the use of conventional or
custom designed arthroscopic tools or instruments. Over the course
of their use in the body the cured, contoured biomaterial exhibits
physical-chemical properties suitable for use in extended in vivo
applications.
[0206] Suitable biomaterials for use in a method of this invention
include, but are not limited to, those described in Applicant's
co-pending PCT Application Nos. PCT/US97/00457. Biomaterials can be
provided as one component systems, or as two or more component
systems that can be mixed prior to or during delivery, or at the
site of repair. Generally such biomaterials are flowable in their
uncured form, meaning they are of sufficient viscosity to allow
their delivery through a cannula of on the order of about 2 mm to
about 6 mm inner diameter, and preferably of about 3 mm to about 5
mm inner diameter. Such biomaterials are also curable, meaning that
they can be cured or otherwise modified, in situ, at the tissue
site, in order to undergo a phase or chemical change sufficient to
retain a desired position and configuration.
[0207] Preferred biomaterials, therefore, are intended to mimic
many of the physical-chemical characteristics of natural tissue.
When cured, preferred materials can be homogeneous (i.e., providing
the same chemical-physical parameters throughout), or they can be
heterogeneous. An example of a heterogeneous biomaterial for use as
a disc replacement is a biomaterial that mimics the natural disc by
providing a more rigid outer envelope (akin to the annulus) and a
more liquid (e.g., cushioning or softer) interior core (akin to the
nucleus).
[0208] Suitable biomaterials for use in the present invention are
those polymeric materials that provide an optimal combination of
properties relating to their manufacture, application, and in vivo
use. In the uncured state, such properties include processability,
and the ability to be stably sterilized and stored. In the course
of applying such material, such properties as flowability,
moldability, and in vivo curability. In the cured state, such
properties include cured strength (e.g., tensile and compressive),
stiffness, biocompatability and biostability. Examples of suitable
biomaterials include, but are not limited to, polyurethane
polymers.
[0209] Biomaterials of the present invention can also include other
optional adjuvants and additives, such as stabilizers, fillers,
antioxidants, catalysts, plasticizers, pigments, and lubricants, to
the extent such optional ingredients do not diminish the utility of
the composition for its intended purpose.
[0210] In particular, preferred biomaterials, in the cured form,
exhibit mechanical properties that approximate those of the natural
tissue that they are intended to replace. For instance, for load
bearing applications, preferred cured composites exhibit a load
bearing strength of between about 50 and about 500 psi (pounds per
square inch), and preferably between about 100 and about 200 psi.
Such composites also exhibit a shear stress of between about 10 and
100 psi, and preferably between about 30 and 50 psi, as such units
are typically determined in the evaluation of natural tissue and
joints. Such composites further exhibit a tensile strength of
between about 4,000 psi and about 10,000 psi, and preferably
between about 6,000 psi and about 8,000 psi. Cured biomaterials for
use in non-orthopedic applications, e.g., as catheters, can
generally exhibit strength and stress parameters that are
appreciably lower than those used in more demanding
applications.
[0211] Preferred biomaterials are also stable under conditions used
for sterilization, and additionally are stable on storage and in
the course of delivery. They are also capable of flowing through a
delivery conduit to an in vivo location, and being cured in situ,
as by exposure to an energy source such as ultraviolet light or by
chemical reaction. Thereafter the cured biomaterial is suitably
amenable to shaping and contouring, by the use of conventional or
custom designed arthroscopic tools or instruments. Over the course
of their use in the body the cured, contoured biomaterial exhibits
physical-chemical properties suitable for use in extended in vivo
applications.
[0212] As described above, a biomaterial composition of the present
invention can be provided in a heterogeneous form, e.g., having two
or more portions that independently provide one or more properties
that differ between the portions. For example, the present teaching
can be employed in the following manner to provide ajoint
resurfacing implant having improved anchoring and tear resistance.
Reactive liquid polyurethanes, as described above, can be mixed
during delivery and polymerized in situ and in vivo in order
resurface or restore damaged body joint. Commonly, and as also
described herein, such an implant can be immobilized in the joint
by means of one or more anchoring holes drilled into the implant
site. Biomaterials having a surface hardness of about 65 to about
85 Shore A, are relatively soft, and can be used to simulate the
cushioning properties of articulating cartilage they target to
replace.
[0213] In certain applications it will be particularly desirable
that the implant be even more firmly and permanently immobilized
within the joint, in order to resist a "carpeting effect" that can
otherwise be caused by load forces as well as frictional and/or
twisting movements typical in the joint. Such an effect can serve
to create extensive wear on the implant, leading to premature
failure of the implant and even dislodging of the implant itself or
portions thereof.
[0214] Given the present description, those skilled in the art will
be able to determine the best manner to avoid such displacement, on
ajoint by joint and case by case basis. Suitable approaches can
include, for instance, adjusting the size, shape, number and/or
position of anchor points to be drilled in order to ensure optimal
performance. Similarly, given the present description those skilled
in the art will be able to determine the optimal biomaterial
composition for use in a particular application, e.g., one that is
sufficiently hard to avoid being "pulled out" of the anchoring
holes under the expected prolonged use in vivo.
[0215] Compositions described herein can be made with an optimal
combination of hardness, stiffness and strength, in order to resist
deformation. Such properties, in turn, will permit the anchor
points to better resist deformation, or failure. In turn, such
biomaterials can provide improved immobilization of the implant,
patient healing, and joint acceptance and performance. Harder
implants, however, tend to experience significantly greater wear
when introduced between surfaces of communicating or articulating
bones.
[0216] Optionally, and preferably therefore, in order to provide an
optimal combination of both stability and cushioning, the implant
can be provided in the form of a heterogeneous composition,
including a harder portion for use as anchor points, and a softer
portion for cushioning. In an alternative embodiment, a multiphasic
bulk morphology of the implant can be produced using an
Interpenetrating Polymer Network (IPN), by bringing together softer
and harder polymer networks while being polymerized.
[0217] In an alternative, and preferred embodiment, the present
invention therefore provides a in situ formed composite that
provides an optimal combination of anchoring and cushioning
properties considered valuable for implant performance.
[0218] The respective portions of such a composite can be provided
in any suitable form, for instance in a sandwich form, such as in
the following manner:
[0219] 1. A thin layer (e.g., about 0.01 mm to about 1.0 mm) of
strong, stiff and tough polyurethane, having the surface hardness
of 55-75 Shore D is deposited into the lesion, filling completely
the anchoring holes. This layer is preferably either solid or
microcellular, neat or enhanced with all potentially available
biologicals to augment integration and immobilization into the
surrounding environment; e.g. bone, cartilage, synovium, etc.
Predominantly, however, the anchoring is improved by increased
resistance to deformation and thus the "pullout", stemming from the
harder and stiffer material. Aspects of biodurability vs.
biodegradation can be considered for this anchoring layer. Given
the present teaching, those skilled in the art will be able to
provide suitable formulations to fulfill these needs.
[0220] 2. Immediately after this first layer is deposited, the
second layer, in the form of a softer, cartilage-like polyurethane,
is delivered and formed over the anchoring layer to form the
composite. This softer layer provides the functional requirements
of the joint restoring implant.
[0221] The in vitro performance of such a combination has been
evaluated in a wear simulator, using simulated body environment
(lactated ringer solution/37 deg C.). Under a specified load and
motion conditions, when immobilized in cross-linked polyurethane
foam simulating the cancellous bone, the double-layered composite
of harder/softer material failed to tear at 320,000-380,000 cycles.
The single-layered sample of the current material and current
approach has failed this test at approximately 20,000 cycles. These
and other results and observations confirm that such an approach is
capable of providing marked improvement.
[0222] In a related aspect, the system described herein can be used
to provide a joint implant having a mushroom-like appearance, in
which "head" represents the implant; the "stem" represents the
anchoring system. Such an implant will flow with the force-field
acting upon it to extend its durability in the joint, and is
particularly useful for indications where the necessary lesion as
taught in U.S. Pat. No. 5,556,429 is impractical or impossible.
[0223] Reactive liquid polyurethanes, mixed during delivery and
polymerized in situ and in vivo are used to resurface or restore
damaged body joint as described herein. The in situ polymerized
implant, based on polyurethanes having the surface hardness between
60-95 Shore A, is immobilized in the joint, in the prepared lesion,
via drilled anchoring holes in the selected implant site. Anchoring
holes are drilled at the "periphery" of the lesion. At least three
holes are drilled to anchor the implant. As described above, such
biomaterials are relatively soft, and are designed to simulate the
properties of articulating cartilage they target to replace.
Furthermore, these materials provide cushioning effect between
respective bones of the respective joint.
[0224] As described above, and in order to avoid the "carpeting
effect", it is often necessary that anchor holes be drilled,
essentially conical in shape and placed in a staggered pattern, to
be filled with curable biomaterial and become an integral part of
the implant. It is difficult to drill the holes in "toe-nail"
fashion with the bottom tip of the hole pointing toward the
periphery of the lesion. This diminishes the "holding" power of the
anchoring hole system. Similarly, increasing numbers of anchor
holes can serve to weaken the bone surface plateau (e.g. tibial
plateau of the knee joint) causing potential "cave in" of the
tibial plateau under the load. Holes can also serve to retain
whatever folds might be brought on in the course of a carpeting
effect, thereby potentially accelerating implant failure.
[0225] In order to address such a situation, a preferred method
includes the following steps:
[0226] 1. A single, conically-shaped and center-located anchoring
hole is drilled or otherwise generated within the joint surface to
be restored.
[0227] 2. A thin layer of 0.01 mm to 1.0 mm of strong, stiff and
tough polyurethane, having the surface hardness of about 55 to
about 75 Shore D is delivered to the plateau surface or the lesion,
filling completely the anchoring hole, in order to generate the
"stem" of the "mushroom". This stem layer can be provided in any
suitable form, e.g., solid, microcellular, neat or enhanced with
one or more biologicals to augment integration and immobilization
into the surrounding environment; e.g. bone, cartilage, synovium,
etc. Predominantly, however, the anchoring will be improved by
increased resistance to deformation and thus the "pullout",
stemming from the harder and stiffer material.
[0228] 3. During or after delivery of the first layer, a second
layer is delivered, e.g., in the form of a softer, cartilage-like
polyurethane, which forms over the anchoring layer to form the
composite in the form of "the head" of the "mushroom". Optionally,
one or more layers can be delivered, in any suitable order and
using any suitable materials, in order to provide a multi-layered
stem and/or head.
[0229] 4. Preferably, both the head and stem, and each layer
therein, are provided in the form of a single material (e.g.,
polyurethane) in a manner that permits delivered in a single or
multi-layered fashion.
[0230] The improved performance of such a composition has been
verified in vitro, in a wear simulator, utilizing simulated body
environment (lactated ringer solution/37 deg C.). Under a specified
load and motion conditions, when immobilized in cross-linked
polyurethane foam simulating the cancellous bone, the
double-layered composite of harder/softer materials failed to tear
at 320,000-380,000 cycles. The single layered sample of the current
material and current approach has failed this test at approximately
20,000 cycles.
Mold Apparatus
[0231] In a preferred embodiment, the method of the invention
involves an initial step of providing an implantable mold apparatus
comprising a cavity adapted to receive and contain a flowable
biomaterial and a conduit adapted to connect the cavity to a source
of curable, flowable biomaterial. A cavity can take any suitable
form, e.g., a unitary balloon-like cavity capable of being
partially or completely filled with biomaterial in order to provide
an intact prosthesis, or a shell-like or tubular cavity used to
form a corresponding tubular prostheses. The mold can be of any
suitable shape or dimension, and can itself include a plurality of
cavities and/or other chambers or conduits, such as those suitable
for the delivery of air or vacuum, as described herein.
[0232] The method can be used for a variety of applications,
including for instance, for the preparation of an integral
prostheses, e.g., for use in articulating joint repair or
replacement and intervertebral disc repair. Alternatively, the
method can be used to provide a hollow mold, such as a tubular mold
for use in preparing implanted passageways, e.g., in the form of
catheters, such as stents, shunts, or grafts.
[0233] In one preferred embodiment, the method of the invention is
used in the course of intervertebral discectomy. In an
amphiarthroidal joint such as the lumbar joint of the back, the
vertebra are separated by an intervertebral disc formed of
cartilage. Applicant's copending PCT Application No. PCT/US97/00457
(the entirety of which is incorporated herein by reference), inter
alia, describes a method for repairing an intervertebral disc that
comprises the steps of:
[0234] a) using microsurgical techniques to perform a discectomy
while preserving an outer annular shell,
[0235] b) providing one or more curable biomaterials to the
interior of the annular shell, and
[0236] c) curing the biomaterials in order to provide a replacement
disc.
[0237] In a preferred embodiment, the distraction of the disc space
is accomplished by the use of suitable distraction means, such as
an inflatable balloon or bladder. The balloon can be delivered in
deflated form to the interior of the annulus and there inflated, as
by the delivery of biomaterial, in order to distract the disc space
and retain the biomaterial.
[0238] An improved inflatable device for used in intervertebral
disc repair will be described with reference to the Drawing, and in
particular FIGS. 1 through 4. In FIG. 1, an apparatus (10) is shown
having balloon portion (12) and biomaterial conduit (14). The
balloon is dimensioned to be positioned within the annular shell
following discectomy, and there filled with biomaterial in order to
provide a replacement disc.
[0239] As shown, in a preferred embodiment, conduit (14) includes a
venting system (16) that includes air passageway (18) passing from
a distal point along the conduit, into and through its wall (20) in
order to pass along the interior of the conduit. Air passageway
(18) terminates at a point at or near the proximal end of balloon
(12), where it can be used to provide gas under pressure (e.g., in
order to position the balloon and/or distract the joint) and where
it can optionally be used to vent gas (e.g., air) within the
balloon as the balloon is filled with biomaterial. As shown, the
air passageway (18) is preferably provided with one or more vent
holes (22) at locations within the balloon, which serve to
facilitate the delivery of biomaterial by improving venting of gas
from within the balloon. Conduit (14), including the air
passageway, can be severed from balloon portion at or near the
point (24) where they attach to or pass through the wall of the
balloon. In this manner the conduit can be removed from the balloon
as or after the biomaterial cures.
[0240] As shown in FIG. 2, the balloon is preferably provided in a
form collapsed or rolled within sheath (26), which can be drawn
back in situ in order to release the balloon. Sheath (26), conduit
(14) and air passageway (18) can each prepared from materials
commonly used for such purposes, such as polyurethane catheters,
and suitably dimensioned to provide the respective functions. The
conduit portion, for instance, will preferably be about 10 cm to
about 30 cm in length, more preferably between about 15 cm to about
25 cm in length, and about 0.1 cm to about 10 cm, and more
preferably about 0.3 cm to about 0.7 cm in outer diameter. The air
passageway, in contrast, will typically be about 1 mm to about 3 mm
in outer diameter, and of sufficient length to extend about 2 cm to
about 4 cm beyond the proximal end of the conduit (and therefore
into the balloon). The balloon, in turn, will typically be about 2
cm to about 3 cm in its longest dimension, about 1.5 cm to about
2.5 cm in width, and about 0.5 cm to about 1.5 cm in thickness,
once filled with biomaterial. Both the biomaterial conduit (14) and
air passageway (18) are preferably provided with controllable and
adjustable valves (28) and (30), for use in adjusting the flow of
biomaterial and gas, respectively, between the two.
[0241] Optionally, air passageway (18) can be provided such that it
terminates at point substantially at or near where it meets the
balloon, i.e., such that it does not extend into the balloon
itself. In this manner it has been found that the balloon can still
be adequately evacuated, yet in a manner that avoids the need to
keep the distal portion of the air passageway permanently encased
in cured biomaterial within the implant.
[0242] In a related embodiment, the mold apparatus, or a kit that
contains or is adapted for use with such a mold apparatus, can
include means for positioning the balloon in situ, e.g., in the
form of a vascular guide wire that can be placed through the
delivery conduit itself, or preferably through an air passageway
that terminates at or near the point of contact with the balloon.
The guide wire can be designed to substantially assume the curved
contour of the extended but unfilled balloon, and to provide a
plane of orientation, in order to both facilitate placement of the
balloon and provide an outline of the periphery of the balloon in
position and prior to filling. Thereafter the guide wire can be
removed from the site prior to delivery of the biomaterial and air
evacuation. The use of a guide wire in this manner is particularly
facilitated by the use of an air passageway that is unconnected to,
and positioned outside of, the biomaterial conduit.
[0243] Optionally, and in order to facilitate the placement and
storage of the collapsed balloon within a sheath, the invention
further provides a rod, e.g., a plastic core material, dimensioned
to be placed within the balloon, preferably by extending the rod
through the conduit. Once in place, a vacuum can be drawn on the
balloon through the air passageway in order to collapse the balloon
around the rod. Simultaneously, the balloon can also be twisted or
otherwise positioned into a desired conformation to facilitate a
particular desired unfolding pattern when later inflated or filled
with biomaterial. Provided the user has, or is provided with, a
suitable vacuum source, the step of collapsing the balloon in this
manner can be accomplished at any suitable time, including just
prior to use. In certain embodiments it will be desirable to
collapse the balloon just prior to its use, e.g., when using
balloon materials that may tend to stick together or lose
structural integrity over the course of extended storage in a
collapsed form. Alternatively, such balloon materials can be
provided with a suitable surface coating, e.g., a covalently bound
polymeric coating, in order to improve the lubricity of the surface
and thereby minimize the chance that contacting balloon surfaces
will adhere to each other.
[0244] Mold cavities of the present invention, e.g., the balloon of
FIG. 1, can be formed by any suitable means. In a preferred
embodiment, the balloon is fabricated by dipcoating a suitably
shaped mandrel into a curable polymer solution. Applicants have
discovered that a mandrel ideally suited for this purpose can be
prepared from a remoldable bismuth-based material. Examples of
suitable materials include low melting point fusible materials,
such as bismuth alloys that are commercially available from a
number of sources (e.g., as Part nos. E-LMA-117, 158, 255 and 281
from Small Parts, Inc. Miami Lakes, Fla.). Such an alloy, for
instance, begins to melt at about 117 degrees C., and solidifies at
room temperature, expanding slightly in the process of cooling. The
allow can be melted out in hot water and collected for re-use.
[0245] A preferred mandrel will be described with reference to
FIGS. 3 and 4. FIG. 3 shows a mandrel (32) covered with newly
formed balloon (34) and held in chuck (36). The solid mandrel (32)
is used to form a balloon by dipcoating it in a suitable solution
(not shown) as described herein. Once cast, the mandrel can be
melted in order to remove it from the balloon by dipping the
combination in water at about 120 degrees C. for about 5 to 15
minutes. As the mandrel liquifies it can be poured and/or squeezed
out of the balloon and reformed for further use. FIG. 4 shows the
resultant balloon (34), after removal of the mandrel, formed by
this process. In the preferred embodiment shown, the balloon
retains an integral stem portion (38) that provides an attachment
site for the conduit shown in FIG. 1.
[0246] A preferred balloon provides an optimal combination of such
properties as extendibility and strength. In this respect, a
balloon that is substantially non-extendible, but strong, can be
used to distract the disc space upon delivery of biomaterial, and
by virtue of the biomaterial delivery pressure. Preferred materials
for use in preparing balloons of the present invention include, for
instance, block copolymers such as castable thermoplastic
polyurethanes, for instance those available under the tradenames
ESTANE (Goodrich), PELLETHANE (Dow), TEXIN (Bayer), Roylar
(Uniroyal), and ELASTOTHANE (Thiocol), as well as castable linear
polyurethane ureas, such as those available under the tradenames
CHROMOFLEX AR (Cardiotech), BIONATE (Polymer Technology Group), and
BIOMER (Thoratec).
[0247] Preferred elastomeric polymers provide an optimal
combination of such properties as flexibility under static and
dynamic conditions, strength, tensile strength, elongation, elastic
modulus during cyclic deformation, ductility, stability and
durability, compliance, porosity, and patency. See generally, M.
Szycher, J. Biomater. Appl. "Biostability of polyurethane
elastomers: a critical review", 3(2):297-402 (1988); A. Coury, et
al., "Factors and interactions affecting the performance of
polyurethane elastomers in medical devices", J. Biomater. Appl.
3(2):130-179 (1988); and Pavlova M, et al., "Biocompatible and
biodegradable polyurethane polymers", Biomaterials 14(13):1024-1029
(1993), the disclosures of which are incorporated herein by
reference.
[0248] Given the present description those skilled in the art will
be able to employ conventional methods, such as casting, for
forming balloons and similar molds of this invention. See, for
instance, "Casting", pp. 109-110, in Concise Encyclopedia ofPolymer
Science and Engineering, Kroschwitz, ed., John Wiley & Sons
(1990). In a preferred embodiment, a remoldable bismuth mandrel is
formed having desired shape and dimensions. Balloons can be cast to
achieve any desired final thickness, preferably on the order of
0.005 inches (0.01 cm) to about 0.015 (0.05 cm) inches thick, and
preferably between about 0.008 inches (0.02 cm) to about 0.012
inches (0.03 cm). The balloon itself is preferably cleaned, e.g.,
by the use of suitable solvents.
[0249] Optionally, and preferably, reinforcing materials such as
meshes formed of natural or synthetic materials can be incorporated
into the balloon, e.g., by layering them onto various portions
while still wet, and covering the mesh with subsequent dip coats. A
mesh can be cut in a form sufficient to extend around the perimeter
of the balloon, for instance, in order to provide added strength in
the course of filling the balloon and distracting the space.
Suitable materials for preparing meshes include polyamide (e.g.,
NYLON), polyester (e.g., tradenames DACRON and HYTREL),
polyethylene, and polypropylene, as well as liquid crystal polymers
available under the tradename VECTRA.
[0250] The various components of a mold apparatus can be prepared
and assembled using techniques within the skill of those in the
related art. For instance, a balloon, conduit and air passageway
can be individually prepared and assembled by attaching the balloon
to an end of the conduit, e.g., by gluing or sonic welding, and
positioning the air passageway within or alongside the conduit and
extending into the balloon. Thereafter the sheath can be applied to
the conduit and slid over the balloon in its collapsed or rolled
configuration. Other materials or means can be incorporated into
the apparatus, such as radioopaque portions, to facilitate the
surgeons ability to orient the balloon in situ. Also, various
joints and junctures between the parts of the apparatus can be
sealed by the use of suitable adhesives or other materials.
[0251] The use of a preferred mold apparatus will be described with
reference to FIG. 5, which shows the balloon portion (12) in place,
with sheath (26) retracted, within a reamed annular shell (70). A
curable biomaterial (72) is delivered into the balloon at the same
time that air is withdrawn from the balloon through vent holes (22)
of air passageway (18). In use, and with the balloon positioned
within the sheath, the apparatus can be inserted into the body
through minimally invasive means in order to position the proximal
end at the site of intended use, e.g., within the disc space. Once
positioned, the sheath can be withdrawn in order to release the
balloon. Optionally, air or other suitable gas can be delivered to
the balloon through the air passageway in order to position the
balloon and/or distract the joint. Thereafter, the valve can be
opened to begin the flow of curable biomaterial. As biomaterial
enters the balloon, gas in the balloon can be vented through air
passageway by drawing a slight vacuum on the distal end of the
passageway, as by the use of a syringe or other suitable vacuum
source. The biomaterial continues to fill the balloon, which in
turn serves to distract (or assist in distracting) the space, until
desired dimensions are obtained, whereupon the flow of biomaterial
is stopped, the biomaterial is allowed to continue to fully cure
(harden), and the balloon severed from the conduit.
[0252] The method and apparatus of the invention can also be used
to repair other joints, including diarthroidal and amphiarthroidal
joints. Examples of suitable diarthroidal joints include the
ginglymus (a hinge joint, as in the interphalangeal joints and the
joint between the humerus and the ulna); throchoides (a pivot
joint, as in superior radio-ulnar articulation and atlanto-axial
joint); condyloid (ovoid head with elliptical cavity, as in the
wrist joint); reciprocal reception (saddle joint formed of convex
and concave surfaces, as in the carpo-metacarpal joint of the
thumb); enarthrosis (ball and socket joint, as in the hip and
shoulder joints) and arthrodia (gliding joint, as in the carpal and
tarsal articulations).
[0253] In a preferred embodiment, the method and apparatus are
employed to repair the knee joint. FIGS. 6 and 7, for instance,
show a preferred balloon for use in knee surgery. As seen in FIG.
6, the mold (40) includes a generally ovoid inflatable portion
(42), preferably having protruding foot portions (44) extending
therefrom and flowably attached to biomaterial conduit (46). In
use, the foot portions, or footpads, (44) can be implanted into
corresponding anchor sites drilled into the bone, in order to
provide improved attachment thereto.
[0254] As seen in FIG. 7, in a further preferred embodiment the
present invention further provides a template (50) for use in
drilling the holes that will correspond with foot portions (44). As
shown, template (50) includes both a substantially planar,
disc-like, template portion (52) and an extendable delivery probe
(54) useful for positioning the template by minimally invasive
means. The disc portion, in turn, is provided with one or more, and
preferably several apertures of predetermined spacing and diameter,
to correspond with the foot portions of a corresponding inflatable
portion. A template such as that shown is considered novel in its
own right, and particularly in the context of a system in which a
mold and template are packaged or paired together to facilitate the
delivery and placement of the mold in situ.
[0255] One or more footpads are formed or formable in a manner
integral with the balloon or are attached thereto in any suitable
manner. The footpads can themselves be solid, or can be part of the
cavity and filled with biomaterial. The footpads are dimensioned to
be positioned into corresponding anchor points within the bone, to
further secure the mold to the site of tissue injury. Optionally,
or in addition to the use of footpads, the underside of the balloon
may have multiple fenestrations (e.g., micro holes) sufficient to
permit the biomaterial to traverse the barrier of the balloon in
order to contact the subchondral bone and/or fill the anchor
points. The apparatus can also be provided with means, such as a
colinear air lumen or other means sufficient to evacuate the
balloon in the course of biomaterial delivery, thereby facilitating
the process further.
[0256] Optionally, and also preferably, the cavity provided by an
apparatus of this invention can be in a form sufficient to provide
a hollow, e.g., tubular biomaterial upon cure. As such, the
apparatus can be used to form an internal passageway, for instance,
to support (internally or externally) an existing passageway (such
as a vessel), to provide a replacement for natural vessel, and/or
to provide a new passageway such as a shunt, between areas not
previously or naturally connected.
[0257] A tubular mold can be used to form a catheter, which in
turn, can serve as a prosthethic device for a variety of
applications. A catheter of the present invention can take a
variety of forms, including, for instance, as an angiographic
catheter, ureteral catheter, central venous catheter, eustachian
catheter, bladder catheter, intracardiac catheter, pacing catheter,
and prostatic catheter.
[0258] A catheter of this invention can also serve as a shunt, to
provide a diversion or bypass of accumulations of fluid to an
absorbing or excreting system. Suitable applications include, for
instance, the use of a catheter as an arteriovenous shunt, Blalock
shunt (subclavian artery to pulmonary artery), cavopulmonary shunt,
distal splenorenal shunt, jejunoileal shunt, "left-to-right" shunt
(e.g., in the heart as through a septal defect, or from the
systemic circulation to the pulmonary), mesocaval shunt,
peritoneovenous shunt, portacaval shunt, portasystemic shunt,
renal-splenic shunt, "right-to-left" shunt (e.g., in the heart as
through a septal defect, or from the pulmonary artery into the
aorta), Scribner shunt (artery, generally radial, to cephalic
vein), splenorenal shunt (including a "Warren" distal splenorenal
shunt), ventriculocisternal shunt, transjugular intrahepatic
portosystemic shunt, and a Waterston shunt (ascending aorta and
subjacent right pulmonary artery).
[0259] Similarly, the catheter can be used to form a graft for
abdominal aortic aneurysms, and in micro form as a graft for
cerebral aneurysms.
[0260] In yet a further preferred embodiment, a mold of this
invention can be used to prepare a solid (e.g., curved and/or
straight) rod, such as a medullary rod for internal fixation of
various fractures. The balloon, and in turn rod, can also be placed
by minimally invasive means.
[0261] For use as a stent-like prosthesis, a catheter of this
invention can be used in a variety of applications. In yet another
aspect the invention provides a stent formed by a method of the
present invention. Stents of the present invention can be used in a
variety of applications, including for peripheral vasculature,
abdominal aortic aneurysms, and applications in connection with the
prostate, esophagus, trachea, bile or biliary tract, and intestine.
A stent of this invention can lay within the lumen of a tubular
structure to provide support during or after anastomosis, or to
assure patency of an intact but contracted lumen.
[0262] The construction and use of a tubular apparatus of the
present invention will be further described with reference to the
Drawing. A preferred embodiment is shown in FIGS. 8 and 9, wherein
the former depicts the apparatus in its uninflated and unfilled
form, and the latter depicts the apparatus of FIG. 8 in its
inflated and filled condition. As seen in both Figures, apparatus
(60) comprises an inner fluid passageway (62), surrounded by a
generally concentric and inflatable air chamber (64), the air
chamber being surrounded by a generally concentric and sealed or
sealable biomaterial cavity (66). The fluid passageway is adapted
to permit the flow of a bodily fluid such as blood in the course of
insertion and delivery of the apparatus. The air chamber is adapted
for attachment to a source of positive or negative air pressure,
and the biomaterial chamber is adapted to be attached to a source
of flowable biomaterial which can be cured in situ to form a
tubular prosthetic implant such as a catheter. Optionally, means
can be provided to vent or evacuate the biomaterial chamber in the
course of filling with biomaterial, e.g., by the application of
slight vacuum using a separate and additional lumen (not
shown).
[0263] As can be seen by reference to FIG. 10, the fluid passageway
(62) and air chamber (64) are separated by a first barrier (68),
while air chamber (64) and biomaterial cavity (66) are separated by
a second barrier (70). Outermost wall (72) provides the external
surface of the biomaterial cavity and generally serves as an outer
wall of the apparatus. Along its length, fluid passageway is
sufficiently long to permit it to be delivered to a desired site
within the body. The air chamber and biomaterial cavity, in turn,
are provided along a portion of the fluid passageway, and generally
need only be sufficiently long to serve their purpose in the
preparation of a prosthetic implant.
[0264] In use, the air chamber can be inflated with air (or other
suitable material) to a desired position and dimensions, whereupon
the biomaterial can be delivered to fill the biomaterial cavity and
cured in situ to form an implanted catheter. Optionally, the air
chamber can be inflated before, during and/or after delivery and/or
cure of the biomaterial. Thereafter the air chamber can be deflated
and, together with the fluid passageway, removed from the body
leaving the cured biomaterial in place as a catheter.
[0265] Optionally also, a mold apparatus of the type shown in FIG.
10 can be provided with means for venting the biomaterial chamber,
e.g., in the course of filling that chamber with biomaterial.
Venting means can be provided in a manner analogous to that
described above with respect to the intervertebral disc balloon,
that is, by the use of a separate air passageway operably attached
to the biomaterial chamber on its proximal end, and attached or
attachable to a vacuum source or source of pressurized air (or gas)
on its opposite end.
[0266] The cross-sectional view provided in FIG. 10 demonstrates
the manner in which fluid passageway (62) serves to permit the
continued flow of fluid within the body in the course of use.
Adjacent or surrounding the passageway is one or more air
passageways (64) that can be used to inflate biomaterial cavity
(66) and establish it in a desired position with respect to the
body and the passageway.
[0267] In another preferred embodiment, the present invention
provides a method for forming a prosthesis in situ, the method
comprising the steps of:
[0268] a) providing a mold apparatus comprising an inner fluid
passageway, a portion of the passageway being surrounded by a
circumferential inflatable air chamber, a portion of the air
chamber being surrounded by a circumferential biomaterial cavity,
the fluid passageway being adapted to permit the flow of a bodily
fluid or substance in the course of insertion and delivery of the
catheter, the air chamber being adapted for operable attachment to
a source of positive or negative air pressure, and the biomaterial
chamber being adapted for operable attachment to a source of
flowable, curable biomaterial which can be cured in situ to form a
catheter, wherein the air chamber, upon inflation serves to define
the inner dimensions of the catheter, and upon deflation allows
free separation and removal of the passageway and air chamber,
leaving the newly formed biomaterial prosthesis in place,
[0269] b) inserting the apparatus to a desired point within the
body,
[0270] c) applying positive air pressure to inflate the air chamber
to a desired dimension,
[0271] d) filling the biomaterial cavity with biomaterial with the
apparatus maintained in its inflated position,
[0272] d) curing the biomaterial, and
[0273] e) deflating and withdrawing the apparatus in a manner that
leaves the cured biomaterial in situ, to serve as an implanted
prosthesis.
[0274] In another embodiment, the invention provides a mold
apparatus comprising a inner fluid passageway, a portion of which
is surrounded by a circumferential, radially expansible, and
inflatable air chamber, a portion of the air chamber being
surrounded by a circumferential, radially expansible, biomaterial
cavity, the fluid passageway being adapted to permit the flow of
bodily fluid or substances in the course of insertion and delivery
of the catheter, the air chamber being adapted for operable
attachment to a source of positive or negative air pressure, and
the biomaterial chamber being adapted to be flowably attached to a
source of biomaterial which can be cured in situ to form an
implanted prosthesis.
[0275] In an alternative embodiment, the biomaterial passageway can
itself be contoured or shaped in any suitable manner, e.g., to
provide a helical or spiral flow path along the length of the mold
apparatus, e.g., in order to provide improved control over the flow
of biomaterial and/or to provide improved dimensional stability to
the cured implant. Similarly, the biomaterial passageway can be
branched or segmented in any suitable fashion, e.g., to provide a
"Y" shaped configuration to accommodate vascular branch points such
as that of the aorta.
[0276] The fluid passageway of this embodiment can be provided by
any material suitable to provide an optimal combination of such
properties as nontoxicity, the ability to be bonded or otherwise
attached to the material(s) used to form the air chamber and/or
biomaterial cavity. An example of a suitable material for forming
the fluid passageway is polyethylene. The air chamber and
biomaterial can be formed from any suitable material, or
combination of materials. Optionally, and preferably, the air
chamber will be formed having, as its interior surface, the
exterior surface of the fluid passageway. The remaining surface of
the air chamber is preferably fabricated from a different, and
expandable, material capable of being sealed to the passageway at
its ends, and contacting and expanding the dimensions of the
biomaterial cavity upon inflation. The outer wall of the fluid
passageway, therefore, is preferably of sufficient strength to
maintain its patency and integrity in order to withstand the
pressure used to inflate the air chamber.
[0277] The biomaterial cavity, in turn, can similarly share a
common wall (its interior) with the exterior wall of the air
chamber, particularly if measures are taken to ensure that desired
portions of the apparatus can be withdrawn from the cured
biomaterial in a manner that permits the cured biomaterial to
remain within the body. Optionally, and preferably, the barrier
between the air chamber and biomaterial cavity is formed of two or
more layers, one serving as the exterior, and expandable, wall of
the air chamber, and the other laying substantially adjacent that
wall and serving as the interior wall of the biomaterial cavity,
and in turn, of the implanted prosthetic. In an alternative
embodiment, the outer and inner walls of the biomaterial cavity can
themselves be integrally attached (e.g., tacked) together in a
spiral configuration in order to strengthen the cylindrical
geometry and facilitate both the evacuation of air and biomaterial
delivery.
[0278] The walls of the fluid passageway, air chamber and
biomaterial cavity are each of suitable dimensions (e.g., thickness
and length) for their intended purpose. Generally the walls of the
fluid passageway will be on the order of 0.02 inches (about 0.05
cm) or less in thickness, with the outer walls of the chamber and
cavity being appreciably thinner, e.g., on the order of 0.01 inches
(about 0.02 cm) or less and 0.005 inches (about 0.01 cm) or less,
respectively. In such an embodiment, it is the walls of the fluid
passageway that provide with apparatus with much, if not all, of
the necessary strength and rigidity for insertion and use.
[0279] The overall diameter of the fluid passageway can be adapted
to its desired purpose, but is generally between about 0.1 cm and
about 3 cm, and preferably between about 0.2 cm and about 2 cm. The
diameters of the air chamber and biomaterial cavity, in turn, can
also be adapted to their desired purpose, but will generally be
between about 0.5 cm and about 5 cm (and preferably between about 1
cm and about 3 cm) for the overall diameter of the inflated air
chamber and filled biomaterial cavity. In turn, the biomaterial
cavity can be used to form an implanted catheter of any suitable
inner and outer diameter, with a corresponding wall thickness of
between about 0.1 mm and about 5 mm, and preferably between about
0.5 mm and about 2 mm. In its uninflated and unfilled condition the
diameter of the entire assembly is generally less than that of the
vessel into which it will be inserted.
[0280] Those skilled in the art, given the present description,
will appreciate that the various materials and/or portions used to
fabricate such an apparatus can be secured in any suitable fashion,
e.g., by the use of appropriate medical-grade adhesives, by the use
of multiple wraps of fine thread or suture, by heat sealing, sonic
welding, and the like. Generally, the fluid passageway will be
provided in the form of a cylindrical body, having the air chamber
and biomaterial cavity similarly formed and positioned as
cylindrical and concentric bodies, with the chamber configured to
taper down at its ends for attachment to the outer surface of the
fluid passageway, and the biomaterial cavity also tapered down at
its ends for attachment to the outer surface of the air
chamber.
[0281] In a particularly preferred embodiment, and as shown in
FIGS. 8 and 9, at least two lumens are mounted as integral parts of
the catheter body, including an air lumen (74) and a biomaterial
lumen (76). The air lumen is connected to an inflation port that
passes through the outside wall and into the air chamber. The
opposite end of the air lumen passes along the distal length of the
catheter to be controllably connected to an air or vacuum source.
The biomaterial lumen is flowably connected to an inflation port
that passes through the outside wall and into the biomaterial
cavity, with its opposite end passing along the distal length of
the catheter to be controllably connected to a biomaterial
source.
[0282] Preferably with the apparatus in its uninflated and unfilled
condition, the apparatus is dimensioned to be delivered through
minimally invasive means to a desired position within the body. The
inflatable air chamber and fillable biomaterial cavity can both be
stored and inserted in a collapsed condition adjacent the outside
surface of the fluid passageway. Optionally, the apparatus can be
covered by a removable sheath (not shown) or other means suitable
to facilitate its delivery to the desired position.
[0283] In use, the apparatus can be inserted through minimally
invasive means through an artery or other bodily vessel to a
desired point within the body, for instance, to a stenosed region
of a blood vessel. Once in place, positive air pressure is applied
in order to inflate the air chamber to a desired dimension. In the
course of inflating the air chamber the outer and surrounding
biomaterial cavity is suitably positioned for the receipt of
biomaterial. As biomaterial fills the cavity, the pressure in the
air chamber can be reduced in order to accommodate the increasing
pressure and volume of biomaterial. Once the biomaterial cavity is
filled to the desired extent, the air pressure can be further
reduced in the air chamber, to the point where a vacuum can be
drawn if desired, and the delivery conduit (fluid passageway and
deflated air chamber) can be removed from the site. Ideally, the
outer wall of the air chamber is distinct from the inner wall of
the biomaterial cavity, such that the air chamber can be readily
separated from the filled cavity, and axially removed
therefrom.
[0284] Suitable materials for preparing a mold apparatus of the
present invention are those that are presently used for such
purposes as balloon angioplasty. Suitable materials provide an
optimal combination of such properties as compliance, biostability
and biocompatability, and mechanical characteristics such as
elasticity and strength. A mold apparatus can be provided in any
suitable form, including having a plurality of layers and/or a
plurality of compartments when expanded. A useful apparatus will
include the balloon or other biomaterial cavity itself, together
with a delivery catheter (optionally having a plurality of lumen
extending longitudinally therewith), and fluid or gas pressure
delivery means.
[0285] In each embodiment, it is possible to treat or otherwise
adapt the outer, tissue contacting, surface of the mold in a manner
that facilitates its use. For instance, mold material can be
rendered porous or fenestrated in order to permit it to become
saturated with the biomaterial and/or to permit tissue to growth
into the material or attach itself thereto. Optionally, and also
preferably, the mold material can be chemically or biochemically
treated, e.g., coated, to enhance the function or prevent unwanted
interactions with the surrounding biological environment. Suitable
coatings can be used, for instance, to render the mold material
lubricious, biocompatible. Such coatings can be attached in any
suitable manner, e.g., covalently attached or passively adsorbed,
and in a manner that is either permanent in nature or slowly
releasable or replaceable over time.
[0286] Although the present invention has been described with
reference to the structures disclosed herein, it is not confined to
the details set forth and this application is intended to cover any
and all modifications and changes as may come within the scope of
the following claims.
[0287] As another step of the method of the invention, the tissue
injury site is prepared for receipt of the biomaterial. Those
skilled in the art will appreciate the manner in which computer
analysis of subchondral bone mass can allow the operator to
customize the mechanical properties of the polymer-hydrogel
composite to match the adjacent subchondral bone. This can be
accomplished by adjusting the size of the hydrogel aggregates and
by changing the percentage of the hydrogel in the polymer
composite.
[0288] In a preferred method, the patient is first prepped and
draped as per routine arthroscopic procedure. The first area to by
resurfaced is then positioned horizontally and facing upright. If
the opposing bone requires resurfacing the joint can be
repositioned after the initial application has cured. This will
allow gravity to assist in filling the anchor points and
distributing the liquid composite evenly over the surface to be
covered. Based on the present description, all the necessary
maneuvers will typically be carried out using only two or three
access portals.
[0289] The surface to be bonded is first cleaned of inflammatory
synovia and frayed or damaged cartilage using a laser knife and/or
other instnuments, such as an arthroscopic shaver. The surface is
then be prepared in order to improve its ability to accept and
retain biomaterial. For instance, the subchondral bone is roughened
by a burr and any osteophytes removed, also by the use of a burr.
The bone is then irrigated to remove debris and the site suctioned
dry. The bone can also be abraded in order to roughen its surface,
or it can be coated with a suitable cement or other interface
material.
[0290] In a preferred embodiment, anchoring points are created in
the supporting joint tissue. For instance, inverted pyramidal or
inverted T-shaped (A) anchor points can be cut into the subchondral
bone using specially designed arthroscopic drill bits or by laser
means.
[0291] If only a small patch is needed only one or two anchor
points may be sufficient, providing the number and arrangement of
points is sufficient to prevent rotational or translational
movement of the cured biomaterial.
[0292] If a larger area of cartilage is being replaced, then six to
nine anchor points may be necessary. The number, size and location
of sites can be determined on a case by case basis, by balancing
the need to retain the cured biomaterial in permanent engagement
with the natural tissue, with the need to avoid undue trauma or
damage to the structural integrity of the natural tissue itself.
Additional or other means, for instance the use of cements, can
also be used to enhance the permanent engagement of the cured
biomaterial with the natural joint tissue.
[0293] For instance, the prepared bone surface, including the
anchor sites, can be treated with high molecular weight hyaluronic
acid. This will improve adhesion of the polymer and act to inhibit
inflammation and local osteoporosis. High molecular weight
hyaluronic acid has also been shown to be an effective stimulator
of osteophytes (i.e., bone-forming cells) as well as an inhibitor
of Interleukin-I (Il-I). As an IL-I inhibitor, the acid will tend
to decrease the inflammatory response in the area around the new
insert.
[0294] As another step of the invention, a desired quantity of the
curable biomaterial is delivered by minimally invasive means to the
prepared site. Uncured biomaterial, either in bulk or in the form
of separate reactive components, can be stored in suitable storage
containers, e.g., sterile, teflon-lined metal canisters. The
biomaterial can be delivered, as with a pump, from a storage
canister to the delivery cannula on demand. Biomaterial can be
delivered in the form of a single composition, e.g., including both
polymer matrix and hydrogel, or can be delivered in the form of a
plurality of components or ingredients. For instance, polymer
matrix and hydrogel can be separately stored and suitably mixed or
combined either in the course of delivery or at the injury site
itself.
[0295] An example of a delivery system that can serve as a model
for the delivery of uncured biomaterials is one presently sold by
Dyonics, Inc. as the "InteliJET Fluid Management System". This
system involves the a low pressure, high flow rate delivery of
saline to a site, and combines delivery with suction that is
automatically adjusted to specific blade styles.
[0296] In terms of its component parts, a preferred delivery system
of the present invention will typically include a motor drive unit,
with a remote controller, associated tube sets, a nonscope inflow
delivery cannula, having independent fluid dynamics pressure and
flow rate adjustments, an energy source for curing, attachments for
the flush, vacuum, waste canister, overflow jars.
[0297] The application cannula will then be inserted into the joint
and under visualization from the fiberoptic scope the polymer
composite will be applied to the subchondral bone. The flow of the
liquid phase polymer composite will be controlled by the operator
via a foot pedal connected to the pumping mechanism on the polymer
canister. The liquid phase polymer composite will flow from the tip
of the application catheter to fill the anchor points and
subsequently cover the subchondral bone.
[0298] As another step of the invention, the delivered biomaterial
is cured by minimally invasive means and in such a manner that the
cured biomaterial is retained in apposition to the prepared site.
As described herein, the biomaterial can be cured by any suitable
means, either in a single step or in stages as it is delivered.
Preferred biomaterials are curable by the application of
ultraviolet light, making them particularly amenable to a system
that delivers such light by minimally invasive means.
[0299] When a sufficient amount of uncured biopolymer has been
delivered, polymerization can be initiated by any suitable means,
e.g., by the use of an ultraviolet light source at the tip of the
application cannula. After the composite has cured (polymerized)
the surface can be contoured as needed by other arthroscopic
instruments. The joint will then be irrigated and the instruments
removed from the portals.
[0300] Using the preferred composite materials described herein it
is envisioned that there may be some natural migration of the
hydrogel component to the composite surface in the course of
curing. This migration will tend to produce a net positive charge
across the surface of the composite. This positive charge, in turn,
will tend to bind negatively charged hyaluronic acid, which is a
compound that naturally occurs in the joint (produced by Type A
synoviocytes). While not intending to be bound by theory, it would
appear that the result of such binding will produce a lubricating
effect to the surface of the composite. Since the hyaluronic acid
is a normal product of the synovial lining cell it will be
continuously replenished. A synthetic hydrophilic bilayer may
alternatively be applied to reduce the coefficient of friction
further.
[0301] The steps of preparing the joint surface and contouring the
cured biomaterial, as described herein, can be accomplished using
conventional arthroscopic instruments and tools. Stryker, Inc.,
Zimmer, Inc. and Dyonics, Inc. for instance, produce a wide array
of arthroscopic surgical blades and instruments. Representative
products are described in Dyonics' U.S. Pat. Nos. 4,274,414,
4,203,444, 4,705,038, 4,842,578, 4,834,729, and 4,983,179, the
disclosure of each of which is incorporated herein by
reference.
[0302] In yet another step of the present invention, the cured,
retained biomaterial is contoured to achieve a desired conformation
approximating that of natural tissue.
[0303] The preferred composite is heat moldable, allowing for
sculpting with a probe that can be introduced through an
arthroscopic portal. Such a probe will typically have a
retractable, flat spatula-shaped end. The tip of the spatula can be
heated to about 100 degrees centigrade, at which temperature the
surface of the composite can be sculpted to the desired contour. As
the composite cools, it will have sufficient memory to retain the
shape it was given.
[0304] If unusual wear occurs in a given area, the implant can
later be resculpted to cover the worn area without the need to
repeat the entire process described above. Instead, the heat probe
can simply be re-inserted under the arthroscopic visualization and
the insert remolded to provide adequate size or properties in the
needed area.
[0305] The steps described herein can be performed or combined in
any suitable fashion. For instance, it is contemplated that the
delivery, curing and contouring of biomaterial can be accomplished
simultaneously and in a single step, for instance, by the use of a
mold that retains a biomaterial in a desired shape as it is
delivered and cured.
[0306] Optionally, and preferably, the final biomaterial can be
subjected to further physical/chemical modifications, e.g., in
order to enhance it performance, biocompatability, and the like.
For instance, calcitonin and inflammatory inhibiting molecules such
as Interleuken I inhibitors can be attached to the bone composite
surface to prevent local osteoporosis and local inflammatory
response which cause loosening. Similarly, the surface of the cured
composite can optionally be modified in order to reduce the
coefficient of friction.
[0307] In a preferred embodiment, a computer program can be used
that is based on existing and ideal articulation angles. The
program can assist the operator in producing a component having an
optimal combination of physical characteristics, for instance
contour and thickness, in order to provide optimal alignment of the
involved joint.
[0308] Similarly, a holographic image can be generated through the
arthroscope to aid the operator in producing the optimal thickness
and contour of the polymer composite. Small joint applications,
e.g., for wrists and ankles, as well as for metacarpal phalangeal
joints, proximal interphalangeal joints, metatarsal phalangeal
joints, and first carpalmetacarpal joints can also be
developed.
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