U.S. patent application number 14/536275 was filed with the patent office on 2015-10-08 for hydrophobic and hydrophilic interpenetrating polymer networks derived from hydrophobic polymers and methods of preparing the same.
The applicant listed for this patent is Daniel CHANG, Curtis W. FRANK, Michael J. JAASMA, Lampros KOURTIS, David MYUNG. Invention is credited to Daniel CHANG, Curtis W. FRANK, Michael J. JAASMA, Lampros KOURTIS, David MYUNG.
Application Number | 20150284654 14/536275 |
Document ID | / |
Family ID | 45723826 |
Filed Date | 2015-10-08 |
United States Patent
Application |
20150284654 |
Kind Code |
A1 |
MYUNG; David ; et
al. |
October 8, 2015 |
HYDROPHOBIC AND HYDROPHILIC INTERPENETRATING POLYMER NETWORKS
DERIVED FROM HYDROPHOBIC POLYMERS AND METHODS OF PREPARING THE
SAME
Abstract
A composition of matter comprising a hydrophobic or hydrophilic
(or both) interpenetrating polymer network containing a
non-ionic/ionic polymer and a hydrophobic thermoset or
thermoplastic polymer, articles made from such composition and
methods of preparing such articles. The invention also includes a
process for preparing a hydrophobic/hydrophilic IPN or semi-IPN
from a hydrophobic thermoset or thermoplastic polymer including the
steps of placing an non-ionizable/ionizable monomer solution in
contact with a hydrophobic thermoset or thermoplastic polymer;
diffusing the monomer solution into the hydrophobic thermoset or
thermoplastic polymer; and polymerizing the monomers to form a
penetrating polymer inside the hydrophobic thermoset or
thermoplastic polymer, thereby forming the IPN or semi-IPN.
Inventors: |
MYUNG; David; (Santa Clara,
CA) ; JAASMA; Michael J.; (San Francisco, CA)
; KOURTIS; Lampros; (San Francisco, CA) ; CHANG;
Daniel; (Danville, CA) ; FRANK; Curtis W.;
(Cupertino, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MYUNG; David
JAASMA; Michael J.
KOURTIS; Lampros
CHANG; Daniel
FRANK; Curtis W. |
Santa Clara
San Francisco
San Francisco
Danville
Cupertino |
CA
CA
CA
CA
CA |
US
US
US
US
US |
|
|
Family ID: |
45723826 |
Appl. No.: |
14/536275 |
Filed: |
November 7, 2014 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
13219348 |
Aug 26, 2011 |
8883915 |
|
|
14536275 |
|
|
|
|
12499041 |
Jul 7, 2009 |
|
|
|
13219348 |
|
|
|
|
61078741 |
Jul 7, 2008 |
|
|
|
61079060 |
Jul 8, 2008 |
|
|
|
61095273 |
Sep 8, 2008 |
|
|
|
61166194 |
Apr 2, 2009 |
|
|
|
61377844 |
Aug 27, 2010 |
|
|
|
61383705 |
Sep 16, 2010 |
|
|
|
Current U.S.
Class: |
508/386 |
Current CPC
Class: |
C10M 107/44 20130101;
C08L 75/04 20130101; C08L 75/06 20130101; A61K 6/893 20200101; C08G
18/831 20130101; C08L 75/16 20130101; C08L 2666/20 20130101; C08L
33/12 20130101; C08L 2666/04 20130101; A61K 6/893 20200101; C08L
75/06 20130101; C08L 33/02 20130101; C08L 75/16 20130101; Y10T
428/31551 20150401; C08L 75/16 20130101; A61K 6/893 20200101; C08L
75/16 20130101; C08G 2270/00 20130101 |
International
Class: |
C10M 107/44 20060101
C10M107/44 |
Claims
1. A composition of matter comprising an IPN or semi-IPN comprising
a hydrophobic thermoset or thermoplastic polymer and a non-ionic
polymer, wherein the IPN or semi-IPN is capable of adhering to a
material comprising the same non-ionic polymer.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 13/219,348, filed Aug. 26, 2011, which is a
continuation-in-part of U.S. patent application Ser. No.
12/499,041, filed Jul. 7, 2009, now abandoned, which claims the
benefit of U.S. Provisional Patent Application No. 61/078,741,
filed Jul. 7, 2008; U.S. Provisional Patent Application No.
61/079,060, filed Jul. 8, 2008; U.S. Provisional Patent Application
No. 61/095,273, filed Sep. 8, 2008; and U.S. Provisional Patent
Application No. 61/166,194, filed Apr. 2, 2009.
[0002] U.S. patent application Ser. No. 13/219,348 also claims the
benefit of U.S. Provisional Application No. 61/377,844, filed Aug.
27, 2010 and U.S. Provisional Application No. 61/383,705, filed
Sep. 16, 2010. The disclosures of each of these prior applications
are incorporated herein by reference.
INCORPORATION BY REFERENCE
[0003] All publications and patent applications mentioned in this
specification are herein incorporated by reference in their
entirety to the same extent as if each individual publication or
patent application was specifically and individually indicated to
be incorporated by reference.
FIELD
[0004] The present invention pertains to semi- and fully
interpenetrating polymer networks, methods of making semi- and
fully interpenetrating polymer networks, articles made from such
semi- and fully interpenetrating polymer networks, and methods of
using such articles.
BACKGROUND
[0005] Fully interpenetrating polymer networks (IPN's) and
semi-interpenetrating polymer networks ("semi-IPN's") have been
created from a variety of starting materials and have been used for
a variety of applications. IPN's and semi-IPN's can combine the
beneficial properties of the polymers from which they are made and
can avoid some of the undesirable properties of their component
polymers.
[0006] Prior IPN's and semi-IPN's have been proposed for use in
biomedical applications, such as a coating for an implant or as
artificial cartilage. See, e.g., U.S. Patent Publ. No.
2005/0147685; U.S. Patent Publ. No. 2009/0035344; and U.S. Patent
Publ. No. 2009/008846. The utility of prior IPN's and semi-IPN's
for their proposed applications is limited by the properties of
those compositions, however. In addition, the starting materials
and processes of making such prior compositions limit not only the
resulting properties of the IPN or semi-IPN but also the commercial
viability of the manufacturing processes and the articles made in
such processes. Also, the mechanical properties of prior IPNs and
semi-IPNs are often limited by the mechanical properties of the
component polymers used, which in the case of most intrinsically
hydrophilic, water-swellable polymers, are usually quite low. For
example, the prior art has not described a viable process for
making a water-swellable IPN or semi-IPN from commercially
available hydrophobic thermoset or thermoplastic polymers, such as
polyurethane or ABS.
[0007] Finally, the utility of prior IPN and semi-IPN compositions
and the value of the articles formed from such compositions have
been limited by the inability to create IPN's and semi-IPN's with
desired characteristics, such as strength, lubricity and
wear-resistance.
SUMMARY OF THE DISCLOSURE
[0008] The mechanical properties desired for certain medical
applications is often outside the range of possibility of many
hydrophilic starting materials. Hence, one aspect of this invention
takes advantage of the high mechanical strength of hydrophobic
starting materials and combines those materials with certain ionic
polymers as a useful way to achieve the goal of high mechanical
strength in addition to other desirable properties. Thus, while the
prior art took water-swellable polymers and tried to make them
stronger, one aspect of this invention takes strong materials and
makes them more water-swellable. A second aspect of this invention
is to take materials and make them more adhesive to materials to
which they are otherwise not adhesive. Examples of two such
materials are polyurethanes and PMMA bone cement. PMMA bone cement
is known as a "grouting" compound that acts as an anchoring
material for orthopaedic implants to bone by way of mutual
mechanical interlocking. One aspect of the invention describes a
way of introducing a constituent of bone cement into polyurethane
in order to facilitate a direct bond with bone cement rather than
just mechanical interlocking. In some embodiments, this bonding
eliminates the need for a mechanical interface between a relatively
compliant device and bone cement, and causes them to bear loads and
transfer loads as a single body rather than as two bodies.
[0009] For purposes of this application, an "interpenetrating
polymer network" or "IPN" is a material comprising two or more
polymer networks which are at least partially interlaced on a
molecular scale, but not covalently bonded to each other, and
cannot be separated unless chemical bonds are broken. A
"semi-interpenetrating polymer network" or "semi-IPN" is a material
comprising one or more polymer networks and one or more linear or
branched polymers characterized by the penetration on a molecular
scale of at least one of the networks by at least some of the
linear or branched macromolecules. As distinguished from an IPN, a
semi-IPN is a polymer blend in which at least one of the component
polymer networks is not chemically crosslinked by covalent
bonds.
[0010] A "polymer" is a substance comprising macromolecules,
including homopolymers (a polymer derived from one species of
monomer) and copolymers (a polymer derived from more than one
species of monomer). A "hydrophobic polymer" is a pre-formed
polymer network having at least one of the following two
properties: (1) a surface water contact angle of at least
45.degree. and (2) exhibits water absorption of 2.5% or less after
24 hours at room temperature according to ASTM test standard D570.
A "hydrophilic polymer" is a polymer network having a surface water
contact angle less than 45.degree. and exhibits water absorption of
more than 2.5% after 24 hours at room temperature according to ASTM
test standard D570. An "ionic polymer" is defined as a polymer
comprised of macromolecules containing at least 2% by weight ionic
or ionizable monomers (or both), irrespective of their nature and
location. An "ionizable monomer" is a small molecule that can be
chemically bonded to other monomers to form a polymer and which
also has the ability to become negatively charged due the presence
of acid functional groups such carboxylic acid and/or sulfonic
acid. A "thermoset polymer" is one that doesn't melt when heated,
unlike a thermoplastic polymer. Thermoset polymers "set" into a
given shape when first made and afterwards do not flow or melt, but
rather decompose upon heating and are often highly crosslinked
and/or covalently crosslinked. A "thermoplastic polymer" is one
which melts or flows when heated, unlike thermoset polymers.
Thermoplastic polymers are usually not covalently crosslinked.
"Phase separation" is defined as the conversion of a single-phase
system into a multi-phase system; especially the separation of two
immiscible blocks of a block co-polymer into two phases, with the
possibility of a small interphase in which a small degree of mixing
occurs.
[0011] The present invention includes a process for modifying
common commercially available hydrophobic thermoset or
thermoplastic polymers, such as polyurethane or ABS to provide new
properties, such as strength, lubricity, electrical conductivity
and wear-resistance. Other possible hydrophobic thermoset or
thermoplastic polymers are described below. The invention also
includes the IPN and semi-IPN compositions as well as articles made
from such compositions and methods of using such articles. The IPN
and semi-IPN compositions of this invention may attain one or more
of the following characteristics: High tensile and compressive
strength; low coefficient of friction; high water content and
swellability; high permeability; biocompatibility; and
biostability.
[0012] Applications of the invention are the creation of
hydrophilic, lubricious sidings or coatings to reduce the static
and dynamic coefficient of friction between two bearing surfaces
and to reduce drag and/or biofilm formation and/or barnacle
formation in marine vessels, diving or swimming suits, other water
crafts or water-borne objects, or pipes. Furthermore, the invention
has potential in electrochemical applications that require
conduction of electrical current, or permeability of ions such as
proton exchange membranes, fuel cells, filtration devices, and
ion-exchange membranes. In addition, the invention can be used as a
method for making bearings and moving parts for applications such
as engines, pistons, or other machines or machine parts. The
invention can also be used in numerous biomedical applications
including cartilage substitutes, orthopaedic joint replacement and
resurfacing devices or components thereof, intervertebral discs,
stents, vascular or urinary catheters, condoms, heart valves,
vascular grafts, and both short-term and long-term implants in
other areas of the body, such as skin, brain, spine, the
gastro-intestinal system, the larynx, and soft tissues in general.
In addition, it can be used as a component of various surgical
tools and instruments. In all of these applications drugs can be
incorporated into the material for localized drug delivery. These
interpenetrating polymer networks can also be used to fabricate
specific drug delivery vehicles in which a therapeutic agent is
released from the polymer matrix. One aspect of the invention
provides compositions of a water-swellable IPN or semi-IPN of a
hydrophobic thermoset or thermoplastic polymer and an ionic
polymer. In some embodiments, the IPN or semi-IPN exhibits a lower
coefficient of friction than the hydrophobic thermoset or
thermoplastic polymer. In some embodiments, the IPN or semi-IPN is
more water-swellable, exhibits higher resistance to creep, and/or
exhibits a higher conductivity and permeability than the
hydrophobic thermoset or thermoplastic polymer. Some embodiments of
the composition also include an anti-oxidation agent.
[0013] In some embodiments, the IPN or semi-IPN is formed by
diffusing an ionizable monomer precursor solution into the
hydrophobic thermoset or thermoplastic polymer and polymerizing the
monomers to form the ionic polymer.
[0014] In some embodiments, the composition also includes water,
which may form a hydration gradient from a first portion of the
composition to a second portion of the composition. An electrolyte
may be dissolved in the water. The IPN or semi-IPN may also be
negatively charged. In various embodiments, the hydrophobic
thermoset or thermoplastic polymer may be physically entangled or
chemically crosslinked with the ionic polymer.
[0015] In some embodiments, the hydrophobic thermoset or
thermoplastic polymer has ordered and disordered domains, and the
ionic polymer may be disposed in the disordered domains.
[0016] In various embodiments the hydrophobic thermoset or
thermoplastic polymer may be selected from the group consisting of
polyurethane, polymethyl methacrylate, polydimethylsiloxane, and
acrylonitrile butadiene styrene. The ionic polymer may be, e.g., a
poly(acrylic acid) or poly(sulfopropyl methacrylate), combinations,
or derivatives thereof. The ionic polymer may include carboxylate
groups and/or sulfonate groups.
[0017] In some embodiments, the ionic polymer forms a concentration
gradient from a first portion of the composition to a second
portion of the composition. The concentration gradient may, e.g.,
provide a stiffness and/or hydration gradient within the
composition.
[0018] Some embodiments include a second hydrophobic thermoset or
thermoplastic polymer which may be disposed in a layer separate
from the first hydrophobic thermoset or thermoplastic polymer or
may be diffused throughout the first hydrophobic thermoset or
thermoplastic polymer.
[0019] Another aspect of the invention provides a process for
producing a water-swellable IPN or semi-IPN from an hydrophobic
thermoset or thermoplastic polymer including the following steps:
placing an ionizable monomer solution in contact with a solid form
of the hydrophobic thermoset or thermoplastic polymer; diffusing
the ionizable monomer solution into the thermoset or thermoplastic
polymer; and polymerizing the ionizable monomers to form a ionic
polymer inside the thermoset or thermoplastic polymer, thereby
forming the IPN or semi-IPN.
[0020] Some embodiments include the step of adding an
anti-oxidation agent. Some embodiments include the step of swelling
the IPN or semi-IPN with water, e.g., to form a hydration gradient
from a first portion of the composition to a second portion of the
composition. The method may also include the step of swelling the
IPN or semi-IPN with an electrolyte solution. Various embodiments
include the steps of chemically crosslinking or physically
entangling the hydrophobic thermoset or thermoplastic polymer with
the ionic polymer.
[0021] In embodiments in which the hydrophobic thermoset or
thermoplastic polymer has ordered and disordered domains, the
method may include the step of swelling the disordered domains with
the ionizable monomer solution prior to the polymerizing step.
[0022] In some embodiments, the hydrophobic thermoset or
thermoplastic polymer is selected from the group consisting of
polyurethane, polymethyl methacrylate, polydimethylsiloxane, and
acrylonitrile butadiene styrene. The ionizable monomer solution may
be an acrylic acid solution and may comprise monomers with
carboxylate groups and/or sulfonate groups.
[0023] In some embodiments, the method includes the step of forming
a concentration gradient of the ionic polymer within the IPN or
semi-IPN through regioselective diffusion of the ionizable monomer
solution through the hydrophobic thermoset of thermoplastic polymer
to, e.g., provide a stiffness and/or hydration gradient within the
composition.
[0024] Some embodiments of the method may include, prior to the
polymerizing step, the steps of placing the ionizable monomer
solution in contact with a solid form of a second hydrophobic
thermoset or thermoplastic polymer; and diffusing the ionizable
monomer solution into the second hydrophobic thermoset or
thermoplastic polymer. In such embodiments, the second hydrophobic
thermoset or thermoplastic polymer may be in a separate layer
adjacent to the first hydrophobic thermoset or thermoplastic
polymer or may be diffused within the first hydrophobic thermoset
or thermoplastic polymer.
[0025] Some embodiments include the step of changing the IPN or
semi-IPN from a first shape to a second shape, such as by heating
the IPN or semi-IPN.
[0026] Yet another aspect of the invention provides a medical
implant including a water-swellable IPN or semi-IPN including an
hydrophobic thermoset or thermoplastic polymer and an ionic
polymer, the implant having a bone contact surface shaped to
conform to a bone surface. Some embodiments also include a fluid
capsule disposed in an interior region of the implant. Some
embodiments have an insertion portion adapted to be inserted into a
bone and a joint interface portion adapted to be disposed within a
joint space, such as bone screws, sutures, or staples engaged with
the IPN or semi-IPN and adapted to engage the bone to attach the
IPN or semi-IPN to the bone and/or a stem extending from the bone
contact surface and adapted to be inserted into the bone. The
medical implant may also be incorporated as a bearing component of
another device, such as a metal-based prosthesis.
[0027] The medical implant may also include a bonding agent adapted
to attach the medical implant to a bone, such as a bone ingrowth
surface formed on the bone contact surface. In some embodiments,
the ionic polymer forms a concentration gradient from a first
portion of the implant to a second portion of the implant. Some
embodiments have a second hydrophobic thermoset or thermoplastic
polymer adjacent to the first hydrophobic thermoset or
thermoplastic polymer, the ionic polymer interpenetrating at least
the first hydrophobic thermoset or thermoplastic polymer.
[0028] In some embodiments, the water-swellable IPN or semi-IPN has
properties mimicking stiffness and lubricity properties of natural
cartilage and may be adapted and configured to replace cartilage in
a joint. The IPN or semi-IPN may have a shape selected from the
group consisting of a cap, a cup, a plug, a mushroom, a stem, and a
patch, and it may be adapted to fit a condyle, tibial plateau,
meniscus, labrum, or glenoid.
[0029] Still another aspect of the invention provides a method of
repairing an orthopedic joint including the steps of replacing
natural cartilage with a water-swellable IPN or semi-IPN having a
hydrophobic thermoset or thermoplastic polymer and an ionic polymer
and engaging the IPN or semi-IPN with a bone surface defining the
joint. The method may also include the steps of bonding, suturing,
stapling, and/or screwing the IPN or semi-IPN to the bone surface.
The method may also include incorporating the material as a bearing
component of another device, such as a metal-based prosthesis. The
method may also include the step of inserting a stem portion into
the bone surface. The orthopedic joint may be selected from a group
consisting of a shoulder joint, a finger joint, a hand joint, an
ankle joint, a foot joint, a toe joint, a knee medial compartment
joint, a patellofemoral joint, a total knee joint, a knee meniscus,
a femoral joint, an acetabular joint, a labral joint, an elbow, an
intervertebral facet, and a vertebral joint.
[0030] Yet another aspect of the invention provides a marine hull
coating including a water-swellable IPN or semi-IPN including a
hydrophobic thermoset or thermoplastic polymer and an ionic
polymer, the coating having a hull contact surface adapted to
attach to a marine hull. The coating may also include an
ultraviolet light protection agent and/or an anti-oxidation
agent.
[0031] Some embodiments of the invention include compositions of
matter having an IPN or semi-IPN that includes a hydrophobic
thermoset or thermoplastic polymer and a non-ionic polymer where
the IPN or semi-IPN is capable of adhering to a material comprising
the same non-ionic polymer. Optionally, in any of the preceding
embodiments, the non-ionic polymer can be derived from an
ethylenically unsaturated monomer such as an acrylic monomer or
methacrylic monomer. Optionally, in any of the preceding
embodiments, the ethylenically unsaturated monomer does not have an
ionizable functional group. Optionally, in any of the preceding
embodiments, the non-ionic polymer may be a constituent, component,
or ingredient of an interlocking, filler, grouting material or
anchoring compound for orthopaedic implants such as bone
cement.
[0032] Optionally, in any of the preceding embodiments, in further
variations, the non-ionic polymer is selected from the group
consisting of polymethyl methacrylate and polystyrene. In some
embodiments, the hydrophobic thermoset or thermoplastic polymer is
a polyurethane polymer.
[0033] Optionally, in any of the preceding embodiments, the IPN or
semi-IPN exhibits greater adhesiveness, stiffness, shear strength
than the hydrophobic thermoset or thermoplastic polymer.
[0034] Optionally, in any of the preceding embodiments, the
composition can further comprise an anti-oxidation agent.
[0035] Optionally, in any of the preceding embodiments, the IPN or
semi-IPN is formed by diffusing a non-ionizable monomer precursor
into the hydrophobic thermoset or thermoplastic polymer and
polymerizing the monomer to form the non-ionic polymer within the
hydrophobic thermoset or thermoplastic polymer. Optionally, in any
of the preceding embodiments, in some variations, the hydrophobic
thermoset or thermoplastic polymer is physically entangled with the
non-ionic polymer. In other embodiments, the hydrophobic thermoset
or thermoplastic polymer is chemically crosslinked to the non-ionic
polymer.
[0036] Optionally, in any of the preceding embodiments, the
non-ionic polymer forms a concentration gradient from a first
portion of the composition to a second portion of the composition.
The concentration gradient can provide a modulus, strength, or
adhesiveness gradient within the composition.
[0037] Another embodiment provides for a composition of matter
comprising an IPN or semi-IPN and a bone cement, the IPN or
semi-IPN comprising a hydrophobic thermoset or thermoplastic
polymer and a non-ionic polymer, and the bone cement comprising the
same non-ionic polymer. Optionally, in any of the preceding
embodiments, in some embodiments, the IPN exhibits greater
adhesiveness with the bone cement than the hydrophobic thermoset or
thermoplastic polymer with the bone cement. Optionally, in any of
the preceding embodiments, in further embodiments, the non-ionic
polymer forms a concentration gradient from a first portion of the
composition to a second portion of the composition. In other
variations, the concentration gradient provides an adhesiveness
gradient within the composition.
[0038] Another aspect of the invention provides a process for
preparing an IPN or semi-IPN from a hydrophobic thermoset or
thermoplastic polymer including the following steps: placing a
non-ionizable monomer or a solution of non-ionizable monomer in
contact with a solid form of the hydrophobic thermoset or
thermoplastic polymer; diffusing the non-ionizable monomer solution
into the thermoset or thermoplastic polymer; and polymerizing the
non-ionizable monomers to form a non-ionic polymer inside the
thermoset or thermoplastic polymer, thereby forming the IPN or
semi-IPN. Optionally, in any of the preceding embodiments, the
process can also include forming the solid form as a medical
implant having a bone interfacing surface and a joint interfacing
surface.
[0039] In further embodiments, the invention provides for a medical
implant comprising a bone interfacing surface, a joint interfacing
surface, and an IPN or semi-IPN comprising a hydrophobic thermoset
or thermoplastic polymer and a non-ionic polymer, wherein the IPN
or semi-IPN is capable of adhering to a material comprising the
same non-ionic polymer. Optionally, in any of the preceding
embodiments, the IPN is disposed on at least one portion of the
bone interfacing surface. Optionally, in any of the preceding
embodiments, the non-ionic polymer forms a concentration gradient
from a first portion of the medical implant to a second portion of
the medical implant. Various embodiments include a medical implant
where the concentration gradient provides an adhesiveness, modulus,
stiffness, or strength gradient within the medical implant. In
other embodiments, the bone interfacing surface and the joint
interfacing surface of the implant are configured for a hip
joint.
[0040] Optionally, in any of the preceding embodiments, the
non-ionic polymer in the implant is derived from an ethylenically
unsaturated monomer without an ionizable functional group. For
example, in some embodiments, the non-ionic polymer is
polymethylmethacrylate.
[0041] Another aspect of the invention provides for a medical
implant comprising a bone interfacing surface, a joint interfacing
surface, and an IPN or semi-IPN comprising a hydrophobic thermoset
or thermoplastic polymer and an non-ionic polymer, wherein the IPN
or semi-IPN is disposed on at least one section of the medical
implant and the said section exhibits greater adhesion with a bone
cement than the hydrophobic thermoset or thermoplastic polymer.
[0042] Various other embodiments include a composition of matter
comprising a first IPN or semi-IPN comprising a non-ionic polymer P
and a hydrophobic thermoset or thermoplastic polymer T and a second
IPN or semi-IPN comprising the same said hydrophobic thermoset or
thermoplastic polymer T and a hydrophilic interpenetrating polymer
S. Optionally, in any of the preceding embodiments, P can be
derived from a non-ionizable, ethylenically unsaturated monomer.
Optionally, in any of the preceding embodiments, the ethylenically
unsaturated monomer does not have an ionizable functional group.
Optionally, in any of the preceding embodiments, T is a
polyurethane containing polymer. Optionally, in any of the
preceding embodiments, S is an ionic polymer. Optionally, in any of
the preceding embodiments, P is polymethylmethacrylate and T is
polyurethane.
[0043] Optionally, in any of the preceding embodiments, the
non-ionic polymer P forms a concentration gradient from a first
portion of the composition to a second portion of the composition.
Optionally, in any of the preceding embodiments, the non-ionic
polymer P forms a concentration gradient from a first portion of
the first IPN or semi-IPN to a second portion of the first IPN or
semi-IPN. Optionally, in any of the preceding embodiments, the
hydrophilic interpenetrating polymer S forms a concentration
gradient from a first portion of the composition to a second
portion of the composition.
[0044] Optionally, in any of the preceding embodiments, the
hydrophilic interpenetrating polymer S forms a concentration
gradient from a first portion of the second IPN or semi-IPN to a
second portion of the second IPN or semi-IPN. Optionally, in any of
the preceding embodiments, the composition include at least two
concentration gradients, wherein the non-ionic polymer P forms a
first concentration gradient from a first portion of the
composition to a second portion of composition and the hydrophilic
interpenetrating polymer S forms a second concentration gradient
from a third portion of the composition to a fourth portion of the
composition.
[0045] Optionally, in any of the preceding embodiments, the first
concentration gradient provides an adhesiveness, lubricious, shear
strength, or stiffness gradient within the composition. Optionally,
in any of the preceding embodiments, the first concentration
gradient provides an adhesiveness gradient and the second
concentration gradient provides a lubricious gradient. Optionally,
in any of the preceding embodiments, the first concentration
gradient and the second concentration gradient partially or fully
overlap.
[0046] Optionally, in any of the preceding embodiments, the
composition further comprises a region of the hydrophobic thermoset
or thermoplastic polymer T that is disposed adjacent to an IPN or
semi-IPN, wherein the region of the hydrophobic thermoset or
thermoplastic polymer T does not contain a polymer P or S.
[0047] Yet another aspect of this invention provides for a
composition of matter comprising a first IPN or semi-IPN comprising
a hydrophobic thermoset or thermoplastic polymer and a non-ionic
polymer and a second IPN or semi-IPN comprising the same said
hydrophobic thermoset or thermoplastic polymer and a hydrophilic
interpenetrating polymer. Optionally, in any of the preceding
embodiments, the first IPN or semi-IPN is disposed in a first
section of the said hydrophobic thermoset or thermoplastic polymer
and the second IPN or semi-IPN is disposed in a second section of
the said hydrophobic thermoset or thermoplastic polymer.
[0048] Another aspect of this invention provides for a composition
of matter comprising at least two IPNs or semi-IPNs, wherein a
first IPN or semi-IPN comprises a hydrophobic thermoset or
thermoplastic polymer and a non-ionic polymer and a second IPN or
semi-IPN comprises a hydrophobic thermoset or thermoplastic polymer
and a hydrophilic interpenetrating polymer.
[0049] A further embodiment provides for a process for preparing a
composition of matter comprising at least two IPNs or semi-IPNs
from a hydrophobic thermoset or thermoplastic polymer including
steps: placing a first section of a solid form of the hydrophobic
thermoset or thermoplastic polymer in contact with a first
non-ionizable or ionizable monomer solution; diffusing the first
non-ionizable or ionizable monomer solution into the thermoset or
thermoplastic polymer; placing a second section of the solid form
in contact with a second non-ionizable or ionizable monomer
solution; diffusing the second non-ionizable or ionizable monomer
solution into the thermoset or thermoplastic polymer; and
polymerizing the non-ionizable or ionizable monomers to form at
least two IPNs or semi-IPNs inside the solid form.
[0050] Another aspect of the invention provides for a process for
preparing a composition of matter comprising at least two IPNs or
semi-IPNs from a hydrophobic thermoset or thermoplastic polymer
including steps: placing a first section of a solid form of a
hydrophobic thermoset or thermoplastic polymer in contact with a
first non-ionizable or ionizable monomer solution; diffusing the
first non-ionizable or ionizable monomer solution into the
thermoset or thermoplastic polymer; polymerizing the first
non-ionizable or ionizable monomers to form a first IPN or semi-IPN
inside the solid form; placing a second section of the solid form
in contact with a second non-ionizable or ionizable monomer
solution; diffusing the second non-ionizable or ionizable monomer
solution into the thermoset or thermoplastic polymer; and
polymerizing the second non-ionizable or ionizable monomers to form
a second IPN or semi-IPN inside the solid form.
[0051] Various embodiments also include a medical implant
comprising a bone interfacing surface, a joint interfacing surface,
a first IPN or semi-IPN comprising a non-ionic polymer P and a
hydrophobic thermoset or thermoplastic polymer T, and a second IPN
or semi-IPN comprising the same said hydrophobic thermoset or
thermoplastic polymer T and a hydrophilic interpenetrating polymer
S. Optionally, in any of the preceding embodiments, the implant can
further include at least two concentration gradients, wherein the
non-ionic polymer P forms a first concentration gradient from a
first portion of the implant to a second portion of the implant and
the hydrophilic interpenetrating polymer S forms a second
concentration gradient from a third portion of the implant to a
fourth portion of the implant. Optionally, in any of the preceding
embodiments, the first concentration gradient in the implant
provides an adhesiveness gradient and the second concentration
gradient provides a lubricious gradient. In other embodiments, the
non-ionic polymer P in the implant is derived from an ethylenically
unsaturated monomer without ionizable functional groups.
[0052] Optionally, in any of the preceding embodiments, in
additional embodiments the non-ionic polymer P in the implant is a
constituent of a bone cement. Optionally, in any of the preceding
embodiments, the non-ionic polymer P in the implant is selected
from the group consisting of polymethylmethacrylate and
polystyrene. Optionally, in any of the preceding embodiments, the
hydrophobic thermoset or thermoplastic polymer T is a polyurethane
polymer. Optionally, in any of the preceding embodiments, the first
IPN or semi-IPN exhibits greater adhesiveness, stiffness, or shear
strength than the hydrophobic thermoset or thermoplastic polymer T.
In further embodiments, the first IPN or semi-IPN exhibits greater
adhesiveness than the hydrophobic thermoset or thermoplastic
polymer T and the second IPN or semi-IPN exhibits greater
lubriciousness than the hydrophobic thermoset or thermoplastic
polymer T. Optionally, in any of the preceding embodiments, the
medical implant includes first and second gradients that partially
or fully overlap. Optionally, in any of the preceding embodiments,
the medical implant includes a region on the implant wherein the
region is adjacent to the first and second IPN or semi-IPN and does
not contain an IPN or semi-IPN.
[0053] Another aspect of this invention includes a medical implant
comprising a bone interfacing surface, a joint interfacing surface,
and at least two IPNs or semi-IPNs, wherein a first IPN or semi-IPN
comprises a non-ionic polymer disposed in at least one section of a
hydrophobic thermoset or thermoplastic polymer, and a second IPN or
semi-IPN comprises a non-ionic polymer disposed in at least one
section of the said hydrophobic thermoset or thermoplastic
polymer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] The novel features of the invention are set forth with
particularity in the claims that follow. A better understanding of
the features and advantages of the present invention will be
obtained by reference to the following detailed description that
sets forth illustrative embodiments, in which the principles of the
invention are utilized, and the accompanying drawings of which:
[0055] FIGS. 1A-D illustrate a method of forming an IPN or semi-IPN
according to one aspect of this invention.
[0056] FIG. 2 illustrates a composition gradient formed in an
article along a thickness direction
[0057] FIG. 3 illustrates a composition gradient formed in an
article along a radial direction.
[0058] FIG. 4A illustrates a method of fabricating a thermoplastic
gradient IPN according to the present invention.
[0059] FIG. 4B illustrates variation of gradient properties within
an IPN according to the invention.
[0060] FIG. 4C illustrates the variation of an ionic polymer across
a gradient IPN.
[0061] FIG. 5 illustrates a laminate structure or an IPN or
semi-IPN.
[0062] FIGS. 6A-B illustrate illustrates shaping of a gradient IPN
article.
[0063] FIGS. 7A-D illustrate shape heating of an IPN.
[0064] FIGS. 8A-D illustrate bonding of a gradient IPN article to a
surface.
[0065] FIGS. 9A-D illustrate how an osteochondral graft implant
formed from an IPN or semi-IPN of this invention can be used to
replace or augment cartilage within a joint.
[0066] FIGS. 10A-B illustrate an osteochondral graft having an
opening to accommodate a ligament.
[0067] FIGS. 11A-E show osteochondral grafts formed from an IPN or
semi-IPN of this invention that may be used singly or in any
combination needed to replace or augment cartilage within a knee
joint.
[0068] FIGS. 12A-B show osteochondral grafts formed from the IPN's
or semi-IPN's of this invention and shaped for use in a finger
joint.
[0069] FIGS. 13A-B show a labrum prosthesis formed from an IPN or
semi-IPN of this invention for use in replacing or resurfacing the
labrum of the shoulder or hip.
[0070] FIG. 14 shows the use of an IPN or semi-IPN of this
invention as a bursa osteochondral graft, labrum osteochondral
graft, glenoid osteochondral graft and humeral head osteochondral
graft.
[0071] FIG. 15 shows the use of an IPN or semi-IPN of this
invention as prostheses for resurfacing intervertebral facets.
[0072] FIG. 16A shows a prosthetic cartilage plug formed from a
gradient IPN composition of this invention.
[0073] FIGS. 16B-D show embodiments in which porous surfaces are
formed on the cartilage plug.
[0074] FIG. 16D is a bottom elevational view of the embodiment of
FIG. 16C.
[0075] FIG. 17 shows an embodiment of a prosthetic cartilage plug
in which the stem is provided with helical ridges to form a screw
for fixation of the plug to bone.
[0076] FIGS. 18A-B are side and bottom elevational views of an
embodiment of a prosthetic cartilage plug having three stems for
press fit insertion into holes in the bone for fixation.
[0077] FIG. 19 shows an embodiment of a prosthetic cartilage plug
in which the exposed head portion is substantially the same
diameter as the stem.
[0078] FIG. 20 shows an embodiment of a prosthetic cartilage plug
in which the exposed head portion is narrower than the stem, and
the stem widens toward the base.
[0079] FIG. 21 shows an embodiment of a prosthetic cartilage plug
in which the stem has circumferential ridges to aid fixation.
[0080] FIG. 22 shows an embodiment similar to that of FIG. 19 that
adds a rough porous surface to the stem.
[0081] FIG. 23 shows an embodiment of an osteochondral graft formed
to physically grip the bone without additional fixation, such as
screws or stems.
[0082] FIG. 24 shows an embodiment of an osteochondral graft having
screw holes for screw fixation.
[0083] FIG. 25 shows an embodiment of an osteochondral graft having
a screw hole and a screw head depression for screw fixation.
[0084] FIG. 26 shows an embodiment of an osteochondral graft having
a stem for insertion into a hole in the bone.
[0085] FIGS. 27A-B show embodiments of the composition of this
invention used to make two-sided lubricious implants.
[0086] FIGS. 28 and 29 show orthopedic implants that are attached
to surfaces of two bones or other anatomic elements that move with
respect to each other, such as in a joint.
[0087] FIGS. 30A-B illustrate the integration of osteochondral
grafts and other implants of this invention into bone over
time.
[0088] FIGS. 31A-C illustrate three possible configurations of
osteochondral implants to repair cartilaginous joint surface
according to this invention.
[0089] FIG. 32 shows the use of a lubricious IPN or semi-IPN
composition of this invention to resurface the hull of a marine
vessel.
[0090] FIG. 33 shows the use of a lubricious thermoplastic or
thermoset IPN to modify interfacing surfaces of machine parts that
move with respect to each other.
[0091] FIG. 34 shows the use of a lubricious thermoplastic or
thermoset IPN to reduce fluid drag on the inner surface of a
pipe.
[0092] FIG. 35 is a photograph of a hydrated PEU/PAA semi-IPN
gradient material being held by a forceps.
[0093] FIG. 36 shows contact angle analysis in association with
Example 32.
[0094] FIGS. 37A-B show the PEU/PAA semi-IPN material subject to
Transmission Electron Microscopy analysis as associated with
Example 33.
[0095] FIG. 38 shows the PEU/PAA semi-IPN material subject to
Transmission Electron Microscopy analysis with a schematic diagram
associated with Example 34.
[0096] FIG. 39 shows the tensile stress-strain behavior of the
PEU/PAA semi-IPN material associated with Example 35.
[0097] FIG. 40 shows the thermagram of the PEU/PAA semi-IPN
material analyzed by DSC associated with Example 36.
[0098] FIG. 41 shows the results of thermal analysis of the PEU/PAA
semi-IPN material analyzed by DSC associated with Example 36.
[0099] FIG. 42 shows the coefficient of friction of the PEU/PAA
semi-IPN material on PEU/PAA under static load associated with
Example 37.
[0100] FIG. 43 shows the coefficient of friction of the PEU/PAA
semi-IPN material on metal under static load associated with
Example 38.
[0101] FIGS. 44A-C show the results of wear testing of the PEU/PAA
semi-IPN material associated with Example 39 compared to UHMWPE
sample from a metal-on-UHMWPE wear test.
[0102] FIGS. 45A-C show the results of wear testing of the PEU/PAA
semi-IPN material associated with Example 39.
[0103] FIG. 46 shows quantification of the results of wear testing
of the PEU/PAA semi-IPN material associated with Example 39.
[0104] FIG. 47 shows the swelling behavior of polyether urethane
and PEU/PAA semi-IPN in various aqueous and organic solvents
associated with Example 40.
[0105] FIGS. 48A-B show the results of the swelling of polyether
urethane and PEU/PAA semi-IPN in water and acetic acid associated
with Example 41.
[0106] FIG. 49 shows polyacrylic acid content in the PEU/PAA
semi-IPN as a function of the amount of acrylic acid in the
swelling solution associated with Example 42.
[0107] FIG. 50 shows the swelling of PEU/PAA semi-IPN as a function
of the amount of polyacrylic acid in the semi-IPN associated with
Example 43.
[0108] FIGS. 51A-B show the results of Dynamic Compression testing
of the PEU/PAA semi-IPN material as associated with Example 44.
[0109] FIG. 52 shows the results of the application of a multistep
stress relaxation compressive stress test to the PEU/PAA semi-IPN
material followed by relaxation as associated with Example 44.
[0110] FIG. 53 shows the results of the application of application
of compressive stress to the PEU/PAA semi-IPN material associated
with Example 44.
[0111] FIG. 54 shows a partial list of materials that have been
made in accordance with the present invention.
[0112] FIG. 55 is a photograph that shows an orthopedic bone cement
cured on a polyurethane-PMMA IPN plate.
[0113] FIGS. 56A-B show the results of shear testing on a
polyurethane plate compared to a polyurethane-PMMA IPN plate.
[0114] FIGS. 57A-D show the swelling kinetics results for two
commercial medical grades of polyurethane.
[0115] FIG. 58A shows an orthopaedic implant having a hydrophobic
adhesive IPN or semi-IPN according to this invention.
[0116] FIG. 58B shows a cross-sectional view along line A-A' of the
orthopaedic implant of FIG. 58A.
[0117] FIG. 59A shows an orthopedic implant having a hydrophobic
adhesive IPN or semi-IPN and a hydrophilic interpenetrating IPN or
semi-IPN according to this invention.
[0118] FIGS. 59B-C show cross-sectional views along line A-A' of
the orthopedic implant of FIG. 59A.
[0119] FIG. 60 illustrates the variation of a non-ionic polymer
across a gradient IPN.
[0120] FIGS. 61A-B show an example of a double gradient with a
lubricious and adhesive gradient.
[0121] FIGS. 62A-E show osteochondral grafts that can be formed
with a double concentration gradient.
[0122] FIG. 63 shows two sides of a generic articular joint with
both sides of the joint replaced with components or devices
according to embodiments of this invention.
[0123] FIG. 64 illustrates cap-on-cup components with a convex
articular component cap and a concave articular component cup
according to embodiments of this invention.
[0124] FIG. 65 illustrates an osteochrondral graft formed to fit
over a surface of a femur.
[0125] FIGS. 66A-B illustrate examples of osteochrondral grafts
formed to fit as patches or plugs.
[0126] FIG. 67 illustrates a full distal femoral cartilage
replacement component according to embodiments of this
invention.
[0127] FIG. 68 illustrates an osteochrondral graft having a
stiffness and hydration gradient.
[0128] FIG. 69 illustrates a porous bone-interface material.
[0129] FIG. 70 illustrates red-stained portions of the
bone-interface material of FIG. 69 indicating material
osteoconductivity.
[0130] FIG. 71 illustrates the results of compressive test of the
porous bone-interface material of FIG. 69.
[0131] FIG. 72 illustrates a synthetic osteochondral plug with a
porous bone-interfacing material.
[0132] FIG. 73 illustrates an injection-molded hemispherical shell
with porous backing.
[0133] FIGS. 74A-B illustrate an injection-molded design with
pyramidal surface feature indentations.
[0134] FIGS. 75A-C illustrate an osteochrondral plug according to
embodiments of this invention.
[0135] FIG. 76 shows a representation of the chemical structure for
a hydroxy-terminated polybutadiene (HTPB).
[0136] FIG. 77 shows a representation of the chemical structure for
a bis-methylenediphenyl diisocyanate (MDI).
[0137] FIG. 78 shows a representation of the chemical structure for
a hindered-phenol acrylate.
[0138] FIG. 79 shows a representation of the chemical structure for
a polyacrylic acid.
[0139] FIG. 80 shows a representation of the chemical structure for
a material having polyacrylic acid copolymerized with HTPB.
[0140] FIG. 81 shows a representation of the chemical structure for
an IPN having a covalently bonded antioxidant.
DETAILED DESCRIPTION
[0141] The present invention includes a process for modifying
common commercially available hydrophobic thermoset or
thermoplastic polymers to confer upon them qualities such as
lubricity, permeability, conductivity and wear-resistance. Such
hydrophobic polymers ordinarily do not soak up water and are
generally useful for their mechanical strength, impermeability and
insulating ability. An exemplary list of hydrophobic polymers
modifiable by the process of this invention includes the following:
Acrylonitrile butadiene styrene (ABS), Polymethylmethacrylate
(PMMA), Acrylic, Celluloid, Cellulose acetate, Ethylene-Vinyl
Acetate (EVA), Ethylene vinyl alcohol (EVAL), Kydex, a trademarked
acrylic/PVC alloy, Liquid Crystal Polymer (LCP), Polyacetal (POM or
Acetal), Polyacrylates (Acrylic), Polyacrylonitrile (PAN or
Acrylonitrile), Polyamide (PA or Nylon), Polyamide-imide (PAI),
Polyaryletherketone (PAEK or Ketone), Polyhydroxyalkanoates (PHAs),
Polyketone (PK), Polyester, Polyetheretherketone (PEEK),
Polyetherimide (PEI), Polyethersulfone (PES)-- see Polysulfone,
Polyethylenechlorinates (PEC), Polyimide (PI), Polymethylpentene
(PMP), Polyphenylene oxide (PPO), Polyphenylene sulfide (PPS),
Polyphthalamide (PPA), Polystyrene (PS), Polysulfone (PSU),
Polyvinyl acetate (PVA), Polyvinyl chloride (PVC), Polyvinylidene
chloride (PVDC), Spectralon, Styrene-acrylonitrile (SAN),
Polydimethylsiloxane (PDMS), and Polyurethanes (PU). A wide variety
of polyurethanes can be used with varying hard segment, soft
segment, and chain extender compositions, as will be described
herein.
[0142] One aspect of the invention takes advantage of a
characteristic of some modifiable thermoset or thermoplastic
hydrophobic polymers: The presence of ordered and disordered
(amorphous) domains within the polymer. For example, some
hydrophobic thermoset or thermoplastic polymers such as
polyurethanes are phase-separated, containing first domains of hard
segments and second domains of soft segments, with the two domains
exhibiting different solubility properties with respect to
interpenetration of monomers. In polyurethanes, the hard segments
are disposed primarily within the ordered domains and the soft
segments are disposed primarily within the disordered (amorphous)
domains. (The starting polymer may contain more than two domains,
of course, without departing from the scope of the invention.) This
difference in properties between the two domains of the
phase-separated polymer enables the process of this invention to
impart new properties to the polymer that can extend throughout the
bulk of the material or throughout only a portion of the material,
e.g., in a particular region or in a gradient. For example, a
non-lubricious polymer can be made lubricious; an otherwise
non-conductive polymer can be made conductive; and an otherwise
non-permeable polymer can be made permeable. Moreover, the process
can be performed repeatedly to introduce more than one new property
to the starting polymer.
[0143] In some embodiments, phase separation in the polymer allows
for differential swelling of one or more separated phases within
the polymer with, e.g., a solvent and/or monomer, which is then
used to impart new properties. According to the invention, for
example, lubriciousness can be introduced to an otherwise
non-lubricious material by adding and polymerizing ionic monomers.
In one embodiment, a polymer material with high mechanical strength
and a lubricious surface can be made from an otherwise
non-lubricious, hydrophobic polymer and a hydrophilic polymer
derived from ionizable, vinyl monomers. By converting otherwise
hydrophobic materials into biphasic materials with both solid and
liquid (water) phases, the present invention addresses a need in
the art for lubricious, high strength materials for use in medical,
commercial, and industrial applications.
[0144] FIGS. 1A-D illustrate the process with respect to a
thermoplastic polyurethane-based polymer containing a network of
hard segments 10 (shown as open rectangles) and soft segments 12
(shown as lines). In FIG. 1B, the soft segments 12 are swollen with
ethylenically unsaturated monomers with or without ionizable
functional groups such as vinyl-based monomer 14 (shown as circles)
and optional solvent, along with an initiator and cross-linker (not
shown), while mostly not affecting the hard segment material. This
swelling process is not dissolution of the polymer; the hard
segments act as physical crosslinks to hold the material together
as the soft segments are imbibed with the monomer(s) and optional
solvent(s). After polymerization and cross-linking of the monomers,
a second network 16 (shown as dark lines in FIGS. 1C and 1D) is
formed in the presence of the first network to create an IPN in
which the second polymer (i.e., the polymerized monomer) is
primarily sequestered within the soft, amorphous domain of the
first polymer. Despite some degree of molecular rearrangement and
further phase separation, the hard segments largely remain ordered
and crystalline, providing structure and strength to the
material.
[0145] The new properties provided by this IPN depend on the
properties of the polymerized monomers that were introduced and on
any optional post-polymerization processing. Examples of such new
properties include lubriciousness, conductivity, hardness,
absorbency, permeability, photoreactivity and thermal reactivity.
For example, as shown in FIG. 1D, after optional swelling in a
buffered aqueous solution, the second network of the IPN of FIG. 1C
becomes ionized 18, and the IPN is water-swollen and lubricious.
Thus, hydrophilicity (i.e., water absorbency) can be introduced
into an otherwise hydrophobic material. A hydrophobic polymer
material such as polyurethane or ABS can be infiltrated with
various ionic polymers such as polyacrylic acid and/or
poly(sulfopropyl methacrylate) such that it absorbs water.
[0146] In addition to absorbency, various levels of permeability
(water, ion, and/or solute transport) can be introduced into an
otherwise non-permeable material. For example, a hydrophobic
polymer material such as polyurethane or ABS can be infiltrated
with an ionic polymer such as polyacrylic acid and/or
poly(sulfopropyl methacrylate) so that it absorbs water, as
described above. This hydration of the bulk of the material allows
for the transport of solutes and ions. The transport of solutes and
ions and permeability to water is made possible by phase continuity
of the hydrated phase of the IPN. This is useful in various
applications, including drug delivery, separation processes, proton
exchange membranes, and catalytic processes. The permeability can
also be utilized to capture, filter, or chelate solutes as a liquid
flows over or through the material. Furthermore, because of this
permeability, the materials of the present invention can be
bestowed with increased resistance to creep and fatigue relative to
their component hydrophobic polymers due to their ability to
re-absorb fluid after sustained or repetitive loading.
[0147] Conductivity can be introduced into an otherwise
non-conductive material. For example, an insulating polymer
material such as polyurethane can be infiltrated with a conductive
polymer (a polyelectrolyte) so that at least part of the hybrid
material is conductive to electric current.
[0148] The invention also includes the alteration of chemical
groups of the second polymer and the use of tethering points in the
second polymer for another polymer, molecule or biomolecule. Also,
any of the domains can be doped with any number of materials, such
as antioxidants, ions, ionomers, contrast agents, particles,
metals, pigments, dyes, biomolecules, polymers, proteins and/or
therapeutic agents.
[0149] The first polymer can be additionally crosslinked or
copolymerized with the second polymer if, for example, acryloxy,
methacryloxy- acrylamido-, allyl ether, or vinyl functional groups
are incorporated into one end or both ends of the polyurethane
prepolymer and then cured by UV or temperature in the presence of
an initiator. For instance, a polyurethane dimethacrylate or
polyurethane bisacrylamide can be used in the first network by
curing in the presence of a solvent (such as dimethylacetamide) and
then evaporating the solvent. The addition of chemical crosslinks
(rather than just physical crosslinks) to the IPN adds a level of
mechanical stability against creep or fatigue caused by continuous,
dynamic loading.
[0150] In addition, a multi-arm (multifunctional) polyol or
isocyanate can be used to create crosslinks in the polyurethane. In
this case, a fully interpenetrating polymer network is created
(rather than a semi-interpenetrating polymer network). The result
is a composite material with the high strength and toughness of
polyurethane and the lubricious surface and biphasic bulk behavior
of the poly(acrylic acid). Alternatively, other crosslinking
methods can be used, including but not limited to gamma or
electron-beam irradiation. These features are especially important
for bearing applications such as artificial joint surfaces, or as
more biocompatible, thrombo-resistant, long-term implants in other
areas of the body such as the vascular system or the skin. Being
swollen with water also allows imbibement with solutes such as
therapeutic agents or drugs for localized delivery to target areas
of the body.
[0151] In another embodiment of the present invention, the first
polymer can be linked to the second polymer. For example,
polyurethane can be linked through a vinyl-end group. Depending on
the reactivity ratio between the end group and the monomer being
polymerized, different chain configurations can be yielded. For
instance, if the reactivity of the monomer with itself is much
greater than the end group with the monomer, then the second
polymer will be almost completely formed before the addition of the
first polymer to the chain. On the other hand, if the reactivity of
the monomer and the end group are similar, then a random
grafting-type copolymerization will occur. The monomers and end
groups can be chosen based on their reactivity ratios by using a
table of relative reactivity ratios published in, for example, The
Polymer Handbook. The result of these will be a hybrid
copolymer/interpenetrating polymer network.
[0152] Any number or combinations of ethylenically unsaturated
monomers or macromonomers (i.e., with reactive double bonds/vinyl
groups) can be used alone or in combination with various solvents
and selectively introduced into one or more of the phases of the
polymer as long as at least 2% of such monomers is ionizable, i.e.,
contains carboxylic acid and/or sulfonic acid functional groups.
Ethylenically unsaturated monomers with ionizable function groups
include acrylic acid (AA) and other sulfonic acid-based monomers.
The ethylenically unsaturated aspect of these includes acrylic,
methacrylic, acrylamide, allyl ether, etc., as has been disclosed
herein. Other monomers include but are not limited to
dimethylacrylamide, acrylamide, NIPAAm, methyl acrylate, methyl
methacrylate, hydroxyethyl acrylate/methacrylate, and any
vinyl-based monomer containing sulfonic acid groups (e.g.
acrylamido methyl propane sulfonic acid, vinyl sulfonic acid,
3-sulfopropyl acrylate (or methacrylate),
2-methyl-2-propene-1-sulfonic acid sodium salt 98%, or any monomers
in which sulfonic acid is conjugated (allyl ethers,
acrylate/methacrylates, vinyl groups, or acrylamides). The monomer
can also include any monomers containing carboxylic acid groups
conjugated to allyl ethers, acrylate/methacrylates, vinyl groups,
or acrylamides. In addition, the monomers can be used in
combination, such as both carboxyl acid and sulfonic acid
containing monomers, to create a carboxylate/sulfonate copolymer.
The pendant functional groups on polymers resulting from these
monomers and monomer combinations can be subject to subsequent
chemical reactions to yield other functionalities to the final
polymer.
[0153] In one embodiment, a preformed, thermoplastic polymer may be
immersed in acrylic acid (or in a solution of acrylic acid
(1%-100%) or other vinyl monomer solution) along with about 0.1%
v/v crosslinker (e.g., triethylene glycol dimethacrylate or N,N
methylene bisacrylamide) with respect to the monomer and about 0.1%
v/v photoinitiator (e.g. 2-hydroxy-2-methyl propiophenone) with
respect to the monomer. The acrylic acid solution can be based on
water, salt buffer, or organic solvents such as dimethylacetamide,
acetone, ethanol, methanol, isopropyl alcohol, toluene,
dichloromethane, propanol, dimethylsulfoxide, dimethyl formamide,
or tetrahydrofuran. The polymer may be swollen by the monomer due
to solvation of the soft segments in the polymer. The monomer
content in the swollen polymer can range from as little as about 1%
to up to about 90%.
[0154] The monomer-swollen polymer may then be removed, placed in a
mold made of glass, quartz, or a transparent polymer, then exposed
to UV light (or elevated temperature) to initiate polymerization
and crosslinking of the monomers. Alternatively, instead of using a
mold, the monomer-swollen polymer can be polymerized while fully or
partially exposed to air or an inert atmosphere (e.g., nitrogen or
argon), or alternatively in the presence of another liquid such as
an oil (e.g., paraffin, mineral, or silicone oil). For medical
applications, it is possible that polymerization step can be
performed in vivo without a mold.
[0155] Depending on the initiator used, exposure to UV light, IR,
or visible light, a chemical, electrical charge, or elevated
temperature leads to polymerization and crosslinking of the
ionizable monomers within the hydrophobic polymer. As an example,
acidic monomers (e.g. acrylic acid) are polymerized to form an
ionic polymer within a preformed thermoplastic, hydrophobic matrix,
forming an interpenetrating polymer network ("IPN"). Solvents can
be extracted out by heat and convection or by solvent extraction.
Solvent extraction involves the use of a different solvent (such as
water) to extract the solvent from polymer, while heat or
convection relies upon evaporation of the solvent. Depending on the
pKa of the ionic polymer (e.g., pKa of PAA=4.7), an acidic pH would
leave the ionic polymer more protonated while a more basic pH would
leave it more ionized.
[0156] Swelling of the IPN in aqueous solution such as phosphate
buffered saline (or other buffered salt solution) at neutral pH
will lead to ionization of the poly(acrylic acid) and further
swelling with water and salts. The resulting swollen IPN will have
a lubricious surface conferred by the hydrophilic, charged
poly(acrylic acid) and high toughness and mechanical strength
conferred by the thermoplastic. In the case of a polyurethane-based
IPN, the IPN will have a structure in which crystalline hard
segments in the polyurethane act as physical crosslinks in the
first network, while chemical crosslinks will be present in the
second network.
[0157] The materials can also be crosslinked after synthesis using
gamma radiation or electron beam radiation. In one example,
polyurethane/polyacrylic acid can be synthesized and then
crosslinked by gamma irradiation, for instance with doses of, for
example, 5, 10, 15, 20, or 25 kGy. In this case, the polymerization
of polyacrylic acid would be done in the absence of a crosslinker,
and after formation of the polymer blend (physical IPN), the
material would be exposed to gamma radiation. This would have the
dual purpose of sterilizing and crosslinking the polyurethane. It
is known in the art that crosslinking of poly(acrylic acid)
hydrogels using gamma irradiation shows a dose-dependence to the
crosslinking of the polymer. This process can also be applied to
other combinations of first and second network polymers, e.g.,
polyurethane and polymethyl methacrylate, ABS and polyacrylic acid,
etc.
[0158] In addition to the starting thermoset and thermoplastic
hydrophobic polymers identified above, modifications to and
derivatives of such polymers may be used, such as sulfonated
polyurethanes. In the case of the polyurethanes, the polyurethane
polymer can be a commercially available material, a modification of
a commercially available material, or be a new material. Any number
of chemistries and stoichiometries can be used to create the
polyurethane polymer. For the hard segment, isocyanates used are
1,5 naphthalene diisocyanate (NDI), isophorone isocyanate (IPDI),
3,3-bitoluene diisocyanate (TODI), methylene bis (p-cyclohexyl
isocyanate) (H.sub.12MDI), cyclohexyl diiscocyanate (CHDI), 2,6
tolylene diisocyanate or 2,4 toluene diisocyanate (TDI), hexamethyl
diisocyanate, or methylene bis(p-phenyl isocyanate). For the soft
segment, chemicals used include, for example polyethylene oxide
(PEO), polypropylene oxide (PPO), poly(tetramethylene oxide)
(PTMO), hydroxy terminated butadiene, hydroxybutyl terminated
polydimethylsiloxane (PDMS), polyethylene adipate,
polycaprolactone, polytetramethylene adipate, hydroxyl terminate
polyisobutylene, polyhexamethylene carbonate glycol, poly (1,6
hexyl 1,2-ethyl carbonate, and hydrogenated polybutadiene. Any
number of telechelic polymers can be used in the soft segment, if
end-groups that are reactive with isocyanates are used. For
instance, hydroxyl- or amine-terminated poly(vinyl pyrrolidone),
dimethylacrylamide, carboxylate or sulfonated polymers, telechelic
hydrocarbon chains (with hydroxyl and/or amine end groups),
dimethylolpropionic acid (DMPA), or these in combination with each
other or with other soft segments mentioned above (e.g., PDMS) can
be used. Ionic soft segments (or chain extenders) such as
dihydroxyethyl propionic acid (DMPA) (or its derivatives) can be
used to make a water-dispersible polyurethane, so long as the ionic
chain extender does not comprise more than 2% of the material.
[0159] Chain extenders include, for example, 1,4 butanediol,
ethylene diamine, 4,4'methylene bis (2-chloroaniline) (MOCA),
ethylene glycol, and hexane diol. Any other compatible chain
extenders can be used alone or in combination. Crosslinking chain
extenders can be used containing isocyanate-reactive endgroups
(e.g. hydroxyl or amine) and a vinyl-based functional group (e.g.
vinyl, methacrylate, acrylate, allyl ether, or acrylamide) may be
used in place of some or all of the chain extender. Examples
include 1,4 dihydroxybutene and glycerol methacrylate.
Alternatively, crosslinking can be achieved through the use of a
polyol such as glycerol which contains greater than two hydroxyl
groups for reaction with isocyanates.
[0160] In some embodiments, at least 2% of the hydrophilic monomers
in the second network is ionizable and anionic (capable of being
negatively charged). In one such embodiment, poly(acrylic acid)
(PAA) hydrogel is used as the second polymer network, formed from
an aqueous solution of acrylic acid monomers. Other ionizable
monomers include ones that contain negatively charged carboxylic
acid or sulfonic acid groups, such as methacrylic acid,
2-acrylamido-2-methylpropanesulfonic acid, sulfopropyl methacrylate
(or acrylate), vinyl sulfonic acid, or vinyl-conjugated versions of
hyaluronic acid, heparin sulfate, and chondroitin sulfate, as well
as derivatives, or combinations thereof. The second network monomer
may also be positively charged or cationic. These other monomers
can also be in a range of 1%-99% in either water or organic
solvent, or be pure (100%). One embodiment of the monomer used to
form the second network can be described by the following
characteristics: (1) it is capable of swelling the polyurethane,
(2) capable of polymerizing, and (3) is ionizable.
[0161] Other embodiments use a co-monomer in addition to the ionic
polymer that may be non-ionic, such as acrylamide, methacrylamide,
N-hydroxyethyl acrylamide, N-isopropylacrylamide,
methylmethacrylate, N-vinyl pyrrolidone, 2-hydroxyethyl
methacrylate, 2-hydroxyethyl acrylate or derivatives thereof. These
can be copolymerized with less hydrophilic species such as
methylmethacrylate or other more hydrophobic monomers or
macromonomers. These can also be polymerized alone or copolymerized
with the aforementioned hydrophilic and/or ionizable monomers.
[0162] Crosslinked linear polymer chains (i.e., macromolecules)
based on these monomers may also be used in the second network, as
well as biomacromolecules (linear or crosslinked) such as proteins
and polypeptides (e.g., collagen, hyaluronic acid, or chitosan).
The choice of the second material will depend on the target
application, for instance in orthopaedic applications, hyaluronic
acid may be useful because it is a major component of joint
cartilage. In addition, biological molecules may carry certain
benefits such as intrinsic biocompatibility or therapeutic (e.g.,
wound healing and/or antimicrobial) properties that make them
useful as material components.
[0163] Any type of compatible cross-linkers may be used to
crosslink the second network in the presence of any of the
aforementioned first networks such as, for example, ethylene glycol
dimethacrylate, ethylene glycol diacrylate, diethylene glycol
dimethacrylate (or diacrylate), triethylene glycol dimethacrylate
(or diacrylate), tetraethylene glycol dimethacrylate (or
diacrylate), polyethylene glycol dimethacrylate, or polyethylene
glycol diacrylate, methylene bisacrylamide,
N,N'-(1,2-dihydroxyethylene)bisacrylamide, derivatives, or
combinations thereof. Any number of photoinitiators can also be
used depending on their solubility with the precursor
solutions/materials. These include, but are not limited to,
2-hydroxy-2-methyl-propiophenone and
2-hydroxy-1-[4-(2-hydroxyethoxyl)phenyl]-2-methyl-1-propanone. In
addition, other initiators such as benzoyl peroxide, 2-oxoglutaric
acid, azobisisobutyronitrile, or potassium persulfate (or sodium
persulfate) can be used. For instance, benzoyl peroxide is useful
for temperature-initiated polymerizations, while
azobisisobutyronitrile and sodium persulfate are useful as radical
initiators.
[0164] In another embodiment, a solvent can be used as a "trojan
horse" to deliver monomers that otherwise would not mix (or
solubilize with) the polymer to one (or more) phases of the
polymer. The solvent must be carefully chosen based on the specific
qualities and phases of the polymer and monomers. For instance,
acetic acid is capable of swelling but does not dissolve many
polyurethanes. Therefore, acetic acid can be used to carry other
monomers such an acrylamide solution, that otherwise would not
enter polyurethane, into the bulk of the polyurethane. This allows
the acrylamide to be selectively polymerized inside one phase of
the polyurethane. The acetic acid can then be washed out leaving
behind a polyurethane with one or more new properties. Other
solvents that can be used include, but are not limited to,
dichloromethane, methanol, propanol, butanol, (or any alkyl
alcohol), acetone, dimethylacetamide, dimethylformamide,
dimethylsulfoxide, tetrahydrofuran, diethylether, or combinations
of these. Taking into account the solubilities in the phases of the
polymer, solvents with varying degrees of swelling of one can be
chosen. Solubilities of the solvents and components of the material
to be swollen can be obtained from polymer textbooks such as The
Polymer Handbook or can be measured experimentally.
[0165] The present invention can be used to form a
bulk-interpenetrated coating on a polymeric material. This coating
is inextricably entangled with the underlying polymer matrix, and
is in contrast to conventional surface coatings in which a material
is grafted or tethered to a surface. In one example of a
bulk-interpenetrated coating, a thermoplastic polymer is coated on
one or more sides or is immersed in an ionizable monomer such as
acrylic acid in the presence of a photoinitiator and a crosslinking
agent. The thermoplastic is then placed in a mold and then exposed
to an initiator (e.g., UV light or heat) for a predetermined period
of time. The mold can be fully or partially transparent and/or
masked to facilitate regionally specific curing of the monomer. The
modified material is then immersed in buffered saline solution to
neutralize the ionic polymer and render the surface lubricious and
hydrophilic. The modified plastic can then be further remolded by
application of heat, solvent, and/or pressure and then shaped to
the desired dimensions. The modified plastic can then be bonded to
various surfaces such as metal, glass, plastic, or other materials
by applying heat or solvent (such as acetone) to the unmodified
plastic surface and bringing the surface in contact with the
surface of interest.
[0166] Among the applications of the invention are the creation of
hydrophilic, lubricious sidings or coatings to reduce drag and/or
biofilm formation and/or barnacle formation in marine vessels,
diving or swimming suits, other water crafts or water-borne
objects, or pipes. In addition, the invention can be used as a
method for making bearings and moving parts for applications such
as engines, pistons, or other machines or machine parts. The
invention can also be used in artificial joints systems or
long-term implants in other areas of the body, such stents and
catheters for the vascular or urinary system or implants, patches,
or dressings for the skin.
[0167] FIGS. 2 and 3 illustrate how the invention can be used to
create a composition gradient within a starting homopolymer. In
FIG. 2, a gradient is formed in material 20 along a thickness
direction, with the IPN formed on one side 22 and extending in a
diminishing concentration to another side 24, e.g., substantially
only homopolymer. In FIG. 3, the IPN concentration gradient is
radial within material 30, with the outer surface 32 being the
highest concentration of IPN and the center or core 34 having the
lowest concentration of IPN. A reverse gradient can also be made in
the case of a cylinder or a sphere, with the IPN disposed in the
core of the shape and the hydrophobic polymer being disposed in the
outer aspect of the shape. This is useful in creating a conductive
semi-IPN wire that is encapsulated within an insulating hydrophobic
material via a gradient composition.
[0168] FIG. 4A illustrates a method of fabricating a thermoplastic
gradient IPN according to the present invention. One side of the
thermoplastic material 40 is imbibed with a monomer solution 42
along with a photoinitiator (not shown) and a crosslinker (not
shown), and then the monomer is polymerized and crosslinked (e.g.,
with UV light 44) within the thermoplastic to form a gradient IPN
46. Increasing the pH to neutral 47 and introducing salt 48 into
the surrounding fluid leads to ionization of the 2nd polymer
network. Alternatively, non-ionic monomers can be used as the basis
in a part (to form a copolymer). The non-ionic polymer would not be
ionized by the buffer solution, but would still create a
hydrophilic surface. Either type of monomer system can be used in
conjunction with either water or an organic solvent.
[0169] In one embodiment, a TP/PAA IPN can be created in a gradient
if polyurethane ("PU") is swollen in AA on one side only or if the
swelling time is limited such that diffusion of the monomers
through the bulk of the TP is not complete. This is especially
useful in the creation of osteochondral grafts for orthopaedic
joint replacement materials. For instance, in the case of a
cartilage replacement material, one side of the material is made
lubricious and water swollen, while the other remains a solid (pure
thermoplastic). In between is a transition between a TP/PAA IPN and
TP, with decreasing PAA content from one surface to the other.
Alternatively, bulk materials with a TP/PAA IPN outer aspect and
PU-only "core" can be made if the diffusion of AA into the TP is
precisely controlled by timing the infiltration of the monomers
into the bulk. The differential swelling that results from this
configuration can lead to remaining stresses (compressive on the
swollen side, tensile on the non-swollen side) that can help
enhance the mechanical and fatigue behavior of the material. In the
case of a material with a thickness gradient, the base of
thermoplastic-only material can be used for anchoring, adhering, or
suturing the device to the anatomical region or interest. This base
can be confined to a small area or be large (e.g., a skirt) and can
extend outward as a single component or multiple components (e.g.,
straps). The internal stresses built up within the thermoplastic
during processing or after swelling can be reduced by
temperature-induced annealing. For instance, temperatures of 60-120
degrees Celsius can be used for various times (30 minutes to many
hours) to anneal the polymer, and the heat can be applied in an
oven, by a hot surface, by radiation, or by a heat gun. The
thermoplastic can later be crosslinked using, for example, gamma or
electron beam radiation.
[0170] FIG. 4B illustrates how the properties of gradient IPN's can
vary to produce the desired composition. FIG. 4C illustrates how
the concentration gradient of the hydrophobic polymer and the ionic
polymer can vary across the thickness (between the two surfaces) of
a gradient IPN. The composition gradient yields a property gradient
in which the IPN is hydrated and more compliant on one side, and
less hydrated (or not hydrated) and stiff on the other.
[0171] Articles made from the IPN's and semi-IPN's of this
invention may also be formed in a laminate structure, as
illustrated in FIG. 5. In one example, the IPN structure 50 is
comprised of a hydrophilic polymer (P) such as poly(acrylic acid)
that is interpenetrating a first thermoplastic (TP1) such as
polyether urethane, which is formed on top of a second
thermoplastic (TP2) such as polycarbonate urethane. Both TP1 and
TP2 can be themselves comprised of multiple layers of various
hardnesses and properties. In addition, many more than two
thermoplastic layers can be used, and one or more of the
thermoplastics can be crosslinked. Finally, non-thermoplastic
elements can be incorporated into this construct.
[0172] Articles formed from the gradient or homogeneous IPN's and
semi-IPN's of this invention may be shaped as desired. FIG. 6
illustrates shaping of a gradient IPN article. This process may
also be used to shape a homogeneous IPN or semi-IPN.
[0173] As shown in FIG. 6A, heat 61 can be used to re-anneal the
physical crosslinks in the polymer (e.g., the hard segments in the
polyurethane) in the thermoplastic side 50 of the gradient IPN to
lead to different desired curvatures after bending (e.g., over a
mold or template) and cooling. FIG. 6B illustrates both convex 62
and concave 64 curvatures on the thermoplastic side of the gradient
IPN. Other shapes may be formed, of course, as desired. The use of
thermoplastic facilitates molding of a device to a desired shape
by, for example, injection molding, reactive injection molding,
compression molding, or alternatively, dip-casting. The molded
device can then be subjected to subsequent network infiltration and
polymerization steps to yield the new IPN material.
[0174] Shaping of IPN and semi-IPN articles according to this
invention may be formed in situ, such as within a human body. For
example, FIGS. 7A-B illustrate heating 71 of a thermoplastic
gradient IPN 70 to enable it to wrap around the curvature of a
femoral head 72. FIGS. 7C-D illustrate the application of heat 74
to a thermoplastic gradient IPN 73 to enable it to adapt to the
curvature of a hip socket 75.
[0175] Shaped or unshaped IPN and semi-IPN articles made according
to this invention may be attached to other surfaces. FIG. 8A-D
shows how a bonding agent 81 such as a solvent, cement, or glue can
be used to attach the thermoplastic gradient IPN article 80 to a
surface 82 at a bonded interface 83. Addition of the solvent, for
example, causes the material to dissolve locally, and after contact
with a surface and drying of the solvent, the thermoplastic adheres
to the surface. This method can be used to create "paneling" of the
present invention of various objects, including but not limited to
marine vessel hull surfaces. A "coating" can be applied by vacuum
forming the material over the contours of the vessel or a part of
the vessel. A similar approach can be used to attach a gradient IPN
to bone surfaces in joints.
[0176] The composition of this invention, formed, e.g., by the
method of this invention, may be used in a variety of settings. One
particular use is as artificial cartilage in an osteochondral
graft. The present invention provides a bone-sparing arthroplasty
device based on an interpenetrating polymer network that mimics the
molecular structure, and in turn, the elastic modulus, fracture
strength, and lubricious surface of natural cartilage. Emulating at
least some of these structural and functional aspects of natural
cartilage, the semi-IPNs and IPNs of the present invention form the
basis of a novel, bone-sparing, "biomimetic resurfacing"
arthroplasty procedure. Designed to replace only cartilage, such a
device is fabricated as a set of flexible, implantable devices
featuring lubricious articular surfaces and osteointegrable
bone-interfaces.
[0177] In principle, the device can be made for any joint surface
in the body. For example, a device to cover the tibial plateau will
require an analogous bone-preparation and polymer-sizing process.
For a device to cover the femoral head in the hip joint, a cap
shaped device fits snugly over the contours of the femoral head.
For a device to line the acetabulum, a hemispherical cup-shaped
device stretches over the lip and can be snapped into place in the
socket to provide a mating surface with the femoral head. In this
way, both sides of a patient's hip joint can be repaired, creating
a cap-on-cap articulation. However, if only one of the surfaces is
damaged, then only one side may be capped, creating a
cap-on-cartilage articulation. In addition, the materials of the
present invention can be used to cap or line the articulating
surfaces of another joint replacement or resurfacing device
(typically comprised of metal) to serve as an alternative bearing
surface.
[0178] To create a cap-shaped device using the present invention
for the shoulder joint (also a ball-and-socket joint), a process
similar to that of the hip joint is used. For instance, a shallow
cup can be created to line the inner aspect of the glenoid.
Furthermore, devices for other joints in the hand, fingers, elbow,
ankles, feet, and intervertebral facets can also be created using
this "capping" concept. In one embodiment in the distal femur, the
distal femur device volume follows the contours of the bone while
sparing the anterior and posterior cruciate ligaments.
[0179] In one embodiment of prosthetic cartilage formed according
to this invention, a polyether urethane device pre-formed with
shore hardness of 75D is injection molded. This device is then
solution casted in a Vitamin E-containing solution containing
polyether urethane formulated to a dry shore hardness of 55D (e.g.,
25% Elasthane.TM. 55D in dimethylacetamide). The casted layer may
then be dried in a convection oven to remove the solvent. The
device may then be immersed in a solution of acrylic acid,
photoinitiator, and crosslinker for 24 hours, and then placed over
a glass mold and exposed to UV light. The resulting device may then
be soaked and washed in phosphate buffered saline. This process is
used to create either convex or concave devices for arthroplasty
applications. The injection-molded pre-form has on one of its sides
a plurality of spaces (pores or features) that make capable of
being anchored to bone with traditional orthopaedic bone
cement.
[0180] Although a commercially available polyurethane product,
Elasthane, Bionate, Pursil, or Sylgard, was used in some examples,
it is understood in the art that any suitable hydrophobic
thermoset/thermoplastic polymer or material may be used and there
is no limitation as to the particular commercial
products/tradenames described herein.
[0181] In another embodiment of the device, a polycarbonate
urethane pre-formed with surface features on one side is
fabricated, followed by dip-casting of one of its sides in a
solution of polyether urethane and then subjected to a process
similar to the one above. In still another embodiment, a polyether
urethane pre-form of shore hardness 55D (e.g., Elasthane.TM. 55D)
is injection molded, followed by immersion in a monomer solution as
above. After curing of the second polymer network, the device is
dip-casted on one side with polycarbonate urethane of shore
hardness 75D. In any of these embodiments, additional surface
features can be added to the bone interface side of the device
through a number of means, including but not limited to machining
(lathe and end-mill), solution casting, solvent-welding, ultrasonic
welding, or heat-welding.
[0182] Porous polycarbonate urethane IPN and semi-IPN structures
may be made according to this invention. Particles (size range:
250-1500 .mu.m) of polycarbonate urethane, including but not
limited to Bionate.RTM. 55D, Bionate.RTM. 65D, and Bionate.RTM.
75D, may be sintered in a mold using heat (220-250.degree. C.),
pressure (0.001-100 MPa), and/or solvent for 10-30 min. The
structures will have a final pore size of 50-2000 .mu.m, porosity
of 15-70%, and a compressive strength exceeding 10 MPa. The final
structures will have porosity to promote tissue
ingrowth/integration for medical and veterinary applications. This
construct can be used alone or with an overlying bearing surface
made from any of the lubricious polymers described in this
invention. This material could be used as a cartilage replacement
plug in joints of the body where cartilage has been damaged, as
described below.
[0183] The composition of this invention, made, e.g., according to
the method of this invention, may be used as a fully or partially
synthetic osteochondral graft. The osteochondral graft consists of
a lubricious, cartilage-like synthetic bearing layer that may be
anchored to porous bone or a synthetic, porous bone-like structure.
The bearing layer has two regions: a lubricious surface layer and a
stiff, bone anchoring layer. In one embodiment, the top, lubricious
region of the bearing layer consists of an interpenetrating polymer
network that is composed of two polymers. The first polymer may be
a hydrophobic thermoplastic with high mechanical strength,
including but not limited to polyether urethane, polycarbonate
urethane, silicone polyether urethane, and silicone polycarbonate
urethanes, or these materials with incorporated urea linkages, or
these materials with incorporated urea linkages (e.g. polyurethane
urea). The second polymer may be a hydrophilic polymer derived from
ionizable, vinyl monomers, including but not limited to acrylic
acid and/or sulfopropyl methacrylate. The bottom region of the
bearing layer (bone anchoring layer) may be a stiff, non-resorbable
thermoplastic that can be caused to flow with ultrasonic welding
vibration, ultrasonic energy, laser energy, heat, RF energy and
electrical energy. The bone anchoring layer is used to anchor the
bearing layer to bone or a bone-like porous structure. If porous
bone is used, it can be cancellous bone from a human or animal. If
a synthetic bone-like material is used, it can consist of porous
calcium-phosphate (and/or other materials, including but not
limited to porous carbonated apatite, beta-tricalcium phosphate, or
hydroxyapatite), or a porous resorbable or non-resorbable
thermoplastic as described above, including but not limited to
polycarbonate urethane, polyether urethane, PLA, PLLA, PLAGA,
and/or PEEK. The bearing layer is anchored to the porous bone or
bone-like structure via application of pressure combined with
energy that cause the bone anchoring material to melt and flow into
the pores or spaces of the bone or bone-like structure, after which
the energy source is removed and the material resolidifies. The
energy source can include but is not limited to vibration,
ultrasonic energy, laser energy, heat, RF energy, and electrical
energy.
[0184] The following figures illustrate various embodiments of the
present invention as a device to partially or completely resurface
damaged joints in the body of mammals (animals or human). These
devices can be fixated to bone through any number of means, such as
a press-fit, screws (metal or plastic, either resorbable or
nonresorbable), sutures (resorbable or nonresorbable), glue,
adhesives, light-curable adhesives (e.g. polyurethane or
resin-based), or cement (such as polymethylmethacrylate or calcium
phosphate, or dental cements).
[0185] FIGS. 9A-D illustrate how an osteochondral graft implant
formed from an IPN or semi-IPN of this invention can be used to
replace or augment cartilage within a joint, such as a hip or
shoulder joint. As shown in FIG. 9A, the prosthetic cartilage 90 is
formed as a sock having a cap portion 91 and an optional collar 92.
The prosthesis 90 may be inverted, as shown in FIG. 9B, and slipped
over the head 94 of the humerus or femur. In an alternative
embodiment shown in FIGS. 10A-B, the prosthesis 90 may include an
opening 95 to accommodate a ligament 96 or other anatomical
structure.
[0186] Implants and other articles may be made in a variety of
complex shapes according to the invention. FIGS. 11A-E show
osteochondral grafts formed from an IPN or semi-IPN of this
invention that may be used singly or in any combination needed to
replace or augment cartilage within a knee joint. FIG. 11A shows a
osteochondral graft 110 adapted to engage the femoral condyles (or
alternatively, just one condyle). FIG. 11B shows osteochondral
grafts 11 and 112 adapted to engage one or both sides of the tibial
plateau 113. FIG. 11C shows an osteochondral graft 118 adapted to
engage the patella 114 and to articulate with an osteochondral
graft 119 adapted to engage the patellofemoral groove 115. FIG. 11D
show osteochondral grafts 116 and 117 adapted to engage the lateral
and medial menisci. FIG. 11E shows how some of these prostheses may
be assembled in place within the knee joint.
[0187] Osteochondral grafts may also be used in other joints, such
as in the finger, hand, ankle, elbow, feet or vertebra. For
example, FIGS. 12A-B show osteochondral grafts 121 and 122 formed
from the IPN's or semi-IPN's of this invention and shaped for use
in a finger joint. FIGS. 13A-B show a labrum prosthesis 131 formed
from an IPN or semi-IPN of this invention for use in replacing or
resurfacing the labrum of the shoulder or hip. FIG. 14 shows the
use of an IPN or semi-IPN of this invention as a bursa
osteochondral graft 141, labrum osteochondral graft 142, glenoid
osteochondral graft 143 and humeral head osteochondral graft 144.
FIG. 15 shows the use of an IPN or semi-IPN of this invention as
prostheses 151 and 152 for resurfacing intervertebral facets.
[0188] The IPN's and semi-IPN's compositions of this invention may
be formed as prosthetic cartilage plugs for partial resurfacing of
joint surfaces. FIG. 16A shows a prosthetic cartilage plug 160
formed from a gradient IPN composition of this invention. Plug 160
has a stem portion 161 formed on a thermoplastic side of the
article and adapted to be inserted into a hole or opening in a
bone. The head 162 of the plug is formed to be a lubricious IPN or
semi-IPN, as described above. FIG. 16B shows a variation in which
porous surfaces are formed on the underside 163 of head 162 and on
the base 164 of stem 161. In the embodiment of FIGS. 16C-D, the
porous surface is formed only in the center portion 165 of base
164. In all embodiments, stem 161 may be press fit into a hole or
opening in the bone, leaving the lubricious IPN surface to be
exposed to act as prosthetic cartilage.
[0189] FIG. 17 shows an embodiment of a prosthetic cartilage plug
170 in which the stem 171 is provided with helical ridges 173 to
form a screw for fixation of the plug to bone. The top surface of
the head 172 is a lubricious IPN or semi-IPN, as above.
[0190] FIG. 18A-B show an embodiment of a prosthetic cartilage plug
180 having three stems 181 for press fit insertion into holes in
the bone for fixation. The top surface of plug head 182 is a
lubricious IPN or semi-IPN, as above.
[0191] FIG. 19 shows an embodiment of a prosthetic cartilage plug
190 in which the exposed head portion 192 is substantially the same
diameter as the stem 191. Stem 191 may be press fit into a hole in
the bone for fixation. The top surface of plug head 192 is a
lubricious IPN or semi-IPN, as above.
[0192] FIG. 20 shows an embodiment of a prosthetic cartilage plug
200 in which the exposed head portion 202 is narrower than stem
201, and stem 201 widens toward base 203. Stem 201 may be press fit
into a hole in the bone for fixation. The top surface of plug head
202 is a lubricious IPN or semi-IPN, as above.
[0193] FIG. 21 shows an embodiment of a prosthetic cartilage plug
210 in which the stem 211 has circumferential ridges to aid
fixation. Stem 211 may be press fit into a hole in the bone for
fixation. The top surface of plug head 212 is a lubricious IPN or
semi-IPN, as above.
[0194] FIG. 22 shows an embodiment similar to that of FIG. 19 that
adds a rough porous surface to stem 221. The top surface of plug
head 222 is a lubricious IPN or semi-IPN, as above.
[0195] FIG. 23 shows an embodiment of an osteochondral graft 230
formed to physically grip the bone without additional fixation,
such as screws or stems. In this embodiment, the lubricious IPN or
semi-IPN portion of the prosthesis is on a concave surface 231 of
the device. The opposite convex surface 232 of the device is shaped
to match the shape of the bone to which prosthesis 230 will be
attached. Surface 232 is porous to facilitate bony ingrowth. The
porous material in this case can be fabricated from a porogen
method as described in the present invention, with the porogen
being sodium chloride, tricalcium phosphate, hydroxyapatite, sugar,
and derivatives or combinations thereof. Alternatively, the
porosity can be derived from sintering polymer beads (e.g.
polyether urethane or polycarbonate urethane) together using heat
or solvent.
[0196] Screw holes may be provided to the osteochondral graft for
fixation to the bone. In FIG. 24, prosthesis 240 is provided with
two holes 241 for screws 242. The bone-contacting concave side 244
of prosthesis 240 is porous (as above) to promote bony ingrowth and
has a shape adapted for physically gripping the bone. The outer
convex surface 243 of the prosthesis is a lubricious IPN or
semi-IPN, as above.
[0197] In FIG. 25, the osteochondral graft 250 is provided with a
screw hole 251 as well as a depression 252 for accommodating the
head of a screw 253. The bone-contacting concave side 254 of
prosthesis 250 is porous (as above) to promote bony ingrowth and
has a shape adapted for physically gripping the bone. The outer
convex surface 255 of the prosthesis is a lubricious IPN or
semi-IPN, as above.
[0198] FIG. 26 shows an embodiment of an osteochondral graft 260
having a stem 261 for insertion into a hole in the bone. The
bone-contacting concave side 262 of prosthesis 260 is porous (as
above) to promote bony ingrowth and has a shape adapted for
physically gripping the bone. The outer convex surface 263 of the
prosthesis is a lubricious IPN or semi-IPN, as above.
[0199] FIGS. 27A-B show embodiments of the composition of this
invention used to make two-side lubricious implants. In FIG. 27A,
implant 270 is sized and configured to replace an intervertebral
disc. Implant 270 has lubricious IPN or semi-IPN surfaces 271 and
272 (formed, e.g., as described above) on its upper and lower
sides. FIG. 27B shows a knee spacer 273 having a wedge-shaped
cross-section. As with disc prosthesis 270, spacer 273 also has
lubricious IPN or semi-IPN surfaces 274 and 275 on its upper and
lower sides.
[0200] Many of the osteochondral grafts and other implants
described above are affixed to a single bone surface. FIGS. 28 and
29 show orthopedic implants that are attached to surfaces of two
bones or other anatomic elements that move with respect to each
other, such as in a joint. In FIG. 28, implant 280 has upper and
lower bone contacting regions 281 and 282 formed to be porous (as
described above) to promote bony ingrowth. The interior of implant
280 is a fluid-filled capsule 283. Inwardly facing bearing surfaces
284 and 285 are lubricious IPN or semi-IPN surfaces (as above).
Implant 280 can be used, e.g., as an interpositional spacer and as
a replacement for the synovial capsule and cartilage of a joint.
The implant 290 of FIG. 29 is similar to that of FIG. 28, but adds
upper and lower stems 291 and 292 for insertion and fixation in
corresponding holes in the bones defining the joint.
[0201] FIGS. 30A-B illustrate the integration of osteochondral
grafts and other implants of this invention into bone over time. In
FIG. 30A, an osteochondral graft implant 300 formed as described
above is placed over bone 301. Implant 300 has a lubricious IPN or
semi-IPN surface 302 and a bone interface surface 303 formed from a
thermoset or thermoplastic hydrophobic polymer alone, which is
optionally porous as described above. Between surface 302 and
surface 303 is a gradient or transition zone 304 between the IPN or
semi-IPN and the hydrophobic polymer. Over time, bone tissue will
grow from bone 301 into and through the bone contacting surface
303, as illustrated in FIG. 30B.
[0202] FIGS. 31A-C illustrate three possible configurations of
osteochondral implants to repair cartilaginous joint surface
according to this invention. In FIG. 31A, implant 310 is formed as
a cap having a lubricious IPN or semi-IPN surface 311 transitioning
to a bone-contacting surface 312 formed from a thermoset or
thermoplastic hydrophobic polymer, as described above. When
implanted, implant 310 covers the outer surface of bone 313.
[0203] FIGS. 31B and 31C show configurations in which implant 314
is formed as a patch or plug (respectively) having a lubricious IPN
or semi-IPN surface 315 transitioning to a bone-contacting surface
316 formed from a thermoset or thermoplastic hydrophobic polymer,
as described above. When implanted, implant 314 fits within a
prepared opening 317 of bone 313.
[0204] The invention has non-medical applications. For example,
FIG. 32 shows the use of a lubricious IPN or semi-IPN composition
of this invention to resurface the hull of a marine vessel. Panels
320 of a thermoplastic gradient IPN (as described above) have been
attached to the surface of hull 322 to reduce drag and biofilm
formation. Alternatively, the IPN material can be in some
embodiments painted on the hulls as a liquid and allowed to cure or
harden. The gradient IPN can be negatively charged on its surface
or uncharged and can be made from one or more types of monomer
species. Various UV protection and anti-oxidizing agents or other
additives can also be incorporated into these materials to improve
their performance.
[0205] FIG. 33 shows the use of a lubricious thermoplastic or
thermoset IPN (as described above) to modify interfacing surfaces
of machine parts that move with respect to each other, such as
surface 331 of rotating and translating part 330 and surface 333 of
stationary part 332. FIG. 34 shows the use of a lubricious
thermoplastic or thermoset IPN (as described above) to reduce fluid
drag on the inner surface 340 of a pipe 342.
[0206] The materials of the present invention have utility in
applications requiring electrochemical conductivity. The
conductivity of the IPNs and semi-IPNs is based on the flow of ions
through the hydrated matrix of the material. Thin films of
polyetherurethane were swelled with four different compositions of
an acrylic acid and water mixture (15, 30, 50, and 70% acrylic acid
in water). Each swelled film was then cured in UV light to form the
semi-IPN. The films were then neutralized in PBS. The electrical
resistance of the materials was measured using an ohm meter. To
measure resistance, the IPN film was lightly patted with a paper
towel to remove excess PBS and the ohm meter probes were clipped to
the film across a film width of 60-70 mm. The initial and
steady-state resistance values were recorded. In addition, the
resistances of an unmodified polyetherurethane film and liquid PBS
were measured. The resistance of PBS was measured by placing the
ohm meter probes directly into a PBS bath at an approximate
distance of 60 mm between the probes. Resistance measurements are
in the following Table.
TABLE-US-00001 TABLE 1 Lowest resistance Steady-state resistance
Material reading (k.OMEGA.) reading (k.OMEGA.) PEU alone (0% AA)
out of range out of range (dielectric) (dielectric) PEU/PAA (15%
AA) 175 200 PEU/PAA (30% AA) 132 177 PEU/PAA (50% AA) 150 161
PEU/PAA (70% AA) 110 141 PBS bath 300 600
[0207] The results show that the resistances of the semi-IPNs are
lower than (but within the same order of magnitude as) pure PBS
fluid alone. The limit of the ohm meter was 40,000 ohms. Typical
values for insulators (including polyurethanes) are
10.sup.14-10.sup.16 ohms; therefore, the resistance values of the
PEU alone were outside the range of the meter used. Permeability of
the PEU/PAA semi-IPN was measured using a device similar to the one
described by Maroudas et al. in Permeability of articular
cartilage. Nature, 1968. 219(5160): p. 1260-1. The permeability was
calculated according to Darcy's Law (Q=KA.DELTA.p/L), where Q is
the flow rate [mm.sup.3/sec], A the cross-sectional area of the
plug [mm.sup.2], .DELTA.p the pressure gradient applied
[MPa](pressurized fluid), L is the thickness of the hydrogel. The
permeability of the PEU/PAA semi-IPN prepared from 70% acrylic acid
was found to be K=1.45.times.10.sup.-17 m.sup.4/N*sec. For natural
cartilage, literature values range from 1.5.times.10.sup.-16 to
2.times.10.sup.-15 m.sup.4/N*sec. Therefore, the PEU/PAA is 10-100
times less permeable than cartilage, which may make it less prone
to dehydration under prolonged compressive loads compared to
natural cartilage. The permeability of the IPN can be tuned by
varying the concentration of AA in the swelling solution; the
higher the AA content, the higher the permeability. In contrast,
the unmodified PEU material alone is effectively impermeable to
solutes; although it retains some moisture (.about.1%), in practice
it does not act as a solute-permeable matrix.
[0208] Other variations and modifications to the above
compositions, articles and methods include:
[0209] The first polymer can be one that is available commercially
or custom-made and made by a number of ways (e.g., extruded,
injection molded, compression molded, reaction injection molded
(RIM) or solution-casted.) The first polymer can be uncrosslinked
or crosslinked by various means. Either polymer can be crosslinked
by, e.g., gamma radiation or electron beam radiation.
[0210] Any number or combinations of ethylenically unsaturated
monomers with ionizable groups or macromonomers (e.g., containing
reactive double bonds) can be used as the basis of the second or
subsequent network so long as the total contains at least 2% by
weight ionizable chemical groups. These include but are not limited
those containing vinyl, acrylate, methacrylate, allyl ether, or
acrylamide groups. Any number of pendant functional groups can be
conjugated to these ethylenically unsaturated groups including but
not limited to carboxylic acid, sulfonic acid, acetates, alcohols,
ethers, phenols, aromatic groups, or carbon chains.
[0211] The polyurethane-based polymer can be (but is not limited
to) the following: polyether urethane, polycarbonate urethane,
polyurethane urea, silicone polyether urethane, or silicone
polycarbonate urethane. Other polyurethanes with other hard
segments, soft segments, and chain extenders are possible.
[0212] Other polymers can be used in the first network, such as
homopolymers or copolymers of silicone (polydimethylsiloxane) or
polyethylene.
[0213] When a polyurethane-based polymer is used as the first
polymer, the extent of physical and chemical crosslinking of the
polyurethane-based polymer can be varied between physical
crosslinking-only (thermoplastic) to extensive chemical
crosslinking. In the case of chemical crosslinking, the
crosslinkable polyurethane can be used alone or as a mixture with
thermoplastic (uncrosslinked) polyurethane.
[0214] The conditions of polymerization (i.e., ambient oxygen, UV
intensity, UV wavelength, exposure time, temperature) may be
varied.
[0215] The orientation and steepness of the composition gradients
can be varied by various means such as time and/or method of
immersion in the monomer, and the application of external
hydrostatic positive or negative pressure.
[0216] The thermoplastic can be made porous by various techniques
such as foaming or salt-leaching. After swelling of the porous
polymer (such as PU) with a monomer (such as AA) followed by
polymerization or AA, a porous IPN is formed.
[0217] Additional layers of thermoplastics can be added to material
on either the IPN side or the thermoplastic side-only by curing or
drying the new thermoplastic to the surface. The layers can all be
the same material or be different materials (e.g. ABS+polyurethane,
polyether urethane+polycarbonate urethane, etc.
[0218] A number of different solvents can be used during the
synthesis of the polyurethane, the second network, or both,
including but not limited to dimethylacetamide, tetrahydrofuran,
dimethylformamide, ethanol, methanol, acetone, water,
dichloromethane, propanol, methanol, or combinations thereof.
[0219] Any number of initiators can be used such as photoinitiators
(e.g., phenone-containing compounds and Irgacure.RTM. products),
thermal initiators, or chemical initiators. Examples of thermal
initiators include but are not limited to azo-compounds, peroxides
(e.g., benzoyl peroxide), persulfates (e.g., potassium persulfate
or ammonium persulfate), derivatives, or combinations thereof.
[0220] Variations of the crosslinking identity and density (e.g.
0.0001%-25% by mole crosslinking agent with respect to the
monomer), initiator concentration (e.g. 0.0001%-10% by mole with
respect to the monomer) molecular weight of precursor polymers,
relative weight percent of polymers, light wavelength (UV to
visible range), light intensity (0.01 mW/cm.sup.2-1 W/cm.sup.2),
temperature, pH and ionic strength of swelling liquid, and the
level of hydration.
[0221] The second network material can be synthesized in the
absence of a crosslinking agent.
[0222] The water content of these materials can range between 2% to
99%.
[0223] Different components of the IPN can be incorporated in
combination with ionizable monomers, such as poly(vinyl alcohol),
poly(ethylene glycol)-acrylate, poly(2-hydroxyethylacrylate),
poly(2-hydroxyethylmethacrylate), poly(methacrylic acid),
poly(2-acrylamido-2-methyl propane sulfonic acid), other
vinyl-group containing sulfonic acids, poly(acrylamide),
poly(N-isopropylacrylamide) poly(dimethacrylamide), and
combinations or derivatives thereof. For instance, a copolymer of
acrylic acid and vinyl sulfonic acid or 2-acrylamido-2-methyl
propane sulfonic acid can be created for the second network to form
a polyurethane first network and a poly(acrylic
acid-co-acrylamido-methyl-propane sulfonic acid) copolymeric second
network. Any monomer or combination of monomers can be used in
conjunction with a suitable solvent as long as they contain at
least 2% by weight ionizable monomer and are able to enter (swell)
the first polymer.
[0224] The IPN can have incorporated either chemically or
physically within its bulk or its surface certain additives such as
antioxidants (e.g., Vitamin C, Vitamin E, Irganox.RTM., or
santowhite powder) and/or anti-microbial agents (e.g.,
antibiotics). These can be chemically linked to the material by,
for example, esterification of the anti-oxidant with any
vinyl-group containing monomer such as methacrylate, acrylate,
acrylamide, vinyl, or allyl ether.
[0225] More than two networks (e.g., three or more) can also be
formed, each of which are either crosslinked or uncrosslinked.
[0226] The polyurethane itself can be modified in a number of ways,
such as by sulfonation at the urethane group by reaction of 1,3
propane sulfone in the presence of sodium hydride, or the formation
of allophanate linkages at the urethane group by reaction with
excess isocyanate groups. For instance, excess isocyanatoethyl
methacrylate can be reacted with polyurethane in toluene in the
presence of dibutyltin dilaurate for 2.5 hours to yield a
methacryloxy-conjugated polyurethane surface. The methacryloxy
groups can then be used subsequently tether other methacryloxy (or
other vinyl group)-containing monomers or macromonomers via free
radical polymerization. Such modifications can be carried out
before or after the formation of the second network of the IPN.
Other modifications will be apparent to those skilled in the
art.
Examples
Example 1
[0227] In one example, a polycarbonate urethane (Bionate 55D) was
immersed in 70% acrylic acid in water containing 0.1% v/v
2-hydroxy-2-methyl propiophenone and 0.1% v/v triethylene glycol
dimethacrylate with respect to the monomer overnight. The
polycarbonate urethane was removed from the solution, placed
between two glass slides, and exposed to UV light (2 mW/cm.sup.2)
for 15 minutes. The resulting semi-IPN was removed, and washed and
swollen in phosphate buffered saline. The material swelled and
became lubricious within hours. In other examples, segmented
polyurethane urea, as well as silicone polyether urethane and
silicone polycarbonate urethanes were placed in acrylic acid
solutions and polymerized and washed in the same fashion to yield a
lubricious IPN.
Example 2
[0228] In another example, a polyether urethane (Elasthane.TM. 55D)
was immersed in 70% acrylic acid in water containing 0.1% v/v
2-hydroxy-2-methyl propiophenone and 0.1% v/v triethylene glycol
dimethacrylate with respect to the monomer overnight. The polyether
urethane was removed from the solution, placed between two glass
slides, and then exposed to UV light (2 mW/cm.sup.2) for 15
minutes. The resulting semi-IPN was removed and then washed and
swollen in phosphate buffered saline. The material swelled and
became lubricious within hours. In other examples, polycarbonate
urethane, segmented polyurethane urea, as well as silicone
polyether urethane and silicone polycarbonate urethanes were placed
in acrylic acid solutions and polymerized and washed in the same
fashion to yield lubricious IPNs.
Example 3
[0229] In another example, silicone polyether urethane and silicone
polycarbonate urethanes were separately placed overnight in 100%
acrylic acid solutions, to which were added 0.1% v/v
2-hydroxy-2-methyl propiophenone and 0.1% v/v triethylene glycol
dimethacrylate with respect to the monomer. After polymerization
and crosslinking, the semi-IPNs swelled and became lubricious. The
addition of silicone (polydimethylsiloxane) in the polyurethane
adds an extra level of biostability to the material as well as
potentially useful surface chemistry and properties.
Example 4
[0230] In another example, a methacryloxy-functionalized
polycarbonate urethane was exposed to UV light to crosslink the
polycarbonate urethane, and then swollen in 70% acrylic acid with
0.1% v/v 2-hydroxy-2-methyl propiophenone and 0.1% v/v triethylene
glycol dimethacrylate with respect to the monomer overnight. The
material was removed from the solution, placed between two glass
slides, and then exposed to UV light (2 mW/cm.sup.2) for 15 minutes
to yield a fully interpenetrating polymer network of the
polycarbonate urethane and poly(acrylic acid.) The IPN was then
washed in an aqueous salt solution to neutralize the poly(acrylic
acid), achieve equilibrium swelling, and remove any unreacted
monomers.
Example 5
[0231] In another example, a methacryloxy-functionalized polyether
urethane was exposed to UV light (in the presence of 0.1%
2-hydroxy-2-methyl propiophenone and 0.1% triethylene glycol
dimethacrylate) to crosslink the polyetherurethane, and then was
swollen in 70% acrylic acid with the aforementioned photoinitiator
and crosslinker followed by UV-initiated crosslinking to yield a
fully interpenetrating polymer network of the polyetherurethane and
poly(acrylic acid.) The IPN was then washed in an aqueous salt
solution to neutralize the poly(acrylic acid), achieve equilibrium
swelling, and remove any unreacted monomers.
Example 6
[0232] In another example, a 25% solution of
methacryloxy-functionalized polycarbonate urethane in DMAC along
with 0.1% of the aforementioned photoinitiator was exposed to UV
light to crosslink the polycarbonate urethane. After removing the
solvent in a heated (60.degree. C.) convection oven, an additional
layer of polycarbonate urethane was then cast on one side of the
crosslinked polycarbonate urethane to yield a laminate structure
and then only the crosslinked side was swollen in 70% acrylic acid
with the 0.1% 2-hydroxy-2-methyl propiophenone and 0.1% triethylene
glycol dimethacrylate followed by UV-initiated crosslinking to
yield a fully interpenetrating polymer network of the polycarbonate
urethane and poly(acrylic acid.) The IPN was then washed in an
aqueous salt solution to neutralize the poly(acrylic acid), achieve
equilibrium swelling, and remove any unreacted monomers.
Example 7
[0233] In another example, a 25% solution of
methacryloxy-functionalized polycarbonate urethane in DMAC along
with 0.1% of the aforementioned photoinitiator was exposed to UV
light to crosslink the polyether urethane. After removing the
solvent in a heated (60.degree. C.) convection oven, an additional
layer of polyether urethane was then cast on one side of the
crosslinked polycarbonate urethane to yield a laminate structure
and then only the crosslinked side was swollen in 70% acrylic acid
with 0.1% 2-hydroxy-2-methyl propiophenone and 0.1% triethylene
glycol dimethacrylate followed by UV-initiated crosslinking to
yield a fully interpenetrating polymer network of the polyether
urethane and poly(acrylic acid.) The IPN was then washed in an
aqueous salt solution to neutralize the poly(acrylic acid), achieve
equilibrium swelling, and remove any unreacted monomers.
Example 8
[0234] In another set of examples, a layer of
methacroxy-functionalized polyether urethane was cast onto a layer
of injection molded polyether urethane, and separately, another
layer was cast onto a layer of injection molded polycarbonate
urethane. Each was exposed to UV light, to yield laminate
structures. Only the crosslinked sides were swollen in 70% acrylic
acid with 0.1% 2-hydroxy-2-methyl propiophenone and 0.1%
triethylene glycol dimethacrylate followed by UV-initiated
crosslinking to yield a fully interpenetrating polymer networks.
The IPNs were then washed in an aqueous salt solution to neutralize
the poly(acrylic acid), achieve equilibrium swelling, and remove
any unreacted monomers.
Example 9
[0235] In one example, acrylonitrile butadiene styrene (ABS) was
exposed to 100% acrylic acid in water containing 0.1% v/v
2-hydroxy-2-methyl propiophenone and 0.1% v/v triethylene glycol
dimethacrylate with respect to the monomer for 15 minutes. The
surface-exposure was accomplished by drop-casting the monomer
solution on the surface of the ABS for 30 minutes. The ABS was then
placed between two glass slides, and then exposed to UV light (2
mW/cm.sup.2) for 15 minutes. The resulting ABS/PAA gradient IPN was
removed and then washed and swollen in phosphate buffered saline.
The IPN was washed in an aqueous salt solution to neutralize the
poly(acrylic acid), achieve equilibrium swelling, and remove any
unreacted monomers. The material swelled and became lubricious
within hours.
Example 10
[0236] To reshape the thermoplastic gradient IPNs, heat was
applied. An ABS/PAA gradient IPN was heated using a heat gun and
then laid on a cylindrical polypropylene tube. After letting the
material cool to room temperature, acetone was injected between the
ABS/PAA and the polypropylene. After applying manual pressure and
allowing the sample to dry, the result was a thermoplastic gradient
IPN wrapped around and bonded to a polypropylene tube.
Example 11
[0237] In another example, a thermoplastic gradient ABS/PAA IPN was
attached to polycarbonate urethane by injecting acetone between the
ABS and polycarbonateurethane and applying manual pressure to yield
a thermoplastic gradient IPN bonded to a polycarbourethane.
Example 12
[0238] In another example, a curved polycarbonate urethane IPN was
made straight again by applying heat on the polyurethane side using
a heat gun, manually reversing the curvature of the material, and
cooling the IPN in water.
Example 13
[0239] In another example, a polyether urethane solution (e.g. 20%
in dimethylacetamide ("DMAC")) was cast on top of a polycarbonate
urethane in a laminate structure, allowed to dry in a heated
(60.degree. C.) convection oven, and then only the polyether
urethane surface was exposed to 70% acrylic acid in water
containing 0.1% v/v 2-hydroxy-2-methyl propiophenone and 0.1% v/v
triethylene glycol dimethacrylate with respect to the monomer for
15 minutes. The surface-exposure was accomplished by laying the
laminate material polyether urethane-side down on a bed of fabric
that was soaked in the aforementioned monomer solution. The
material was removed from the fabric mat, placed between two glass
slides, and then exposed to UV light (2 mW/cm.sup.2) for 15
minutes. The resulting gradient semi-IPN was removed, washed and
swollen in phosphate buffered saline. The material swelled and
became lubricious within hours. In other examples, polyether
urethane, segmented polyurethane urea, silicone polyether urethane,
and silicone polycarbonate urethane were handled the same way to
yield a lubricious semi-IPNs.
Example 14
[0240] In another example, a layer of polycarbonate urethane (20%
in DMAC) containing 50% by weight sodium chloride was solution cast
on a premade polyether urethane-polycarbonate urethane and dried at
80.degree. C. under convection. The salt was washed away in water
to yield a porous side on the laminated polyurethane. Other
materials have been made with sodium chloride concentrations
varying between 10% and 80%
Example 15
[0241] In another example, a layer of polycarbonate urethane (20%
in DMAC) containing 20% tricalcium phosphate was solution cast on a
premade polyether urethane-polycarbonate urethane and dried at
80.degree. C. under convection. The tricalcium phosphate was left
embedded within the polyurethane as an osteoconductive agent. Other
materials have been made with tricalcium phosphate concentrations
varying from 0.001%-20%
Example 16
[0242] In another example, a polyurethane urea (e.g. 20% in
dimethylacetamide) was cast on top of a polycarbonate urethane in a
laminate structure, and then only the polyurethane urea surface was
exposed to 70% acrylic acid in water containing 0.1% v/v
2-hydroxy-2-methyl propiophenone and 0.1% v/v triethylene glycol
dimethacrylate with respect to the monomer for 15 minutes. The
surface-exposure was accomplished by laying the laminate material
polyurethane urea-side down on a bed of fabric that was soaked in
the aforementioned monomer solution. The polycarbonate urethane was
removed from the fabric mat, placed between two glass slides, and
then exposed to UV light (2 mW/cm.sup.2) for 15 minutes. The
resulting gradient semi-IPN was removed and then washed and swollen
in phosphate buffered saline. The material swelled and became
lubricious within hours. The material was washed in PBS to
neutralize the poly(acrylic acid), achieve equilibrium swelling,
and remove any unreacted monomers.
Example 17
[0243] In another example, a methacryloxy-functionalized polyether
urethane mixed with a thermoplastic polyether urethane in solution
(25% in dimethylacetamide) was exposed to UV light to crosslink the
polycarbonate urethane. An additional layer of polyether urethane
was then cast on one side of the crosslinked polyether urethane to
yield a laminate structure and then only the crosslinked side was
swollen in 70% acrylic acid with the aforementioned photoinitiator
and crosslinker, followed by UV-initiated crosslinking to yield a
fully interpenetrating polymer network of the polyether urethane
and poly(acrylic acid.) The IPN was then washed in an aqueous salt
solution to neutralize the poly(acrylic acid), achieve equilibrium
swelling, and remove any unreacted monomers.
Example 18
[0244] In one example, flat sheets were created by solution casting
ofthermoplastic polyurethanes in (dimethylacetamide (DMAC).
Polyurethane solutions of polyether urethane (Elasthanem),
polycarbonate urethane (Bionate), polyether urethane urea
(Biospan), silicone polycarbonate urethane (Carbosil), and silicone
polyether urethane (Pursil) were synthesized in dimethylacetamide
(DMAC) at solids concentrations of about 25% by the
manufacturer.
Example 19
[0245] Spherical shapes were cast by dip-coating glass as well as
silicone spheres in polyurethane solutions (in DMAC). Polycarbonate
urethane (20% in DMAC) was dip coated onto a spherical glass mold
(49.5 mm outer diameter), and separately, onto a silicone sphere.
The solvent was removed by drying at 80.degree. C. in a convection
oven. This process was repeated two more times to create three
total coatings. Then, the sphere was dip coated in polyether
urethane (20% in DMAC) and then dried at 80.degree. C. under
convection. This process was also repeated two more times. The
resulting capped-shaped, laminate polyurethane was removed from the
mold, and its outer side immersed in a 70% acrylic acid solution in
water, with 0.1% 2-hydroxy-2-methyl-propiophenone and 0.1%
triethylene glycol dimethacrylate for 1.5 hours. The cap was
inverted, placed back over a spherical glass mold, and exposed to
UV light (2 mW/cm.sup.2) for 15 minutes. Next the cap was removed
from the mold and placed in phosphate buffered saline. The result
was a spherical, gradient IPN with one lubricious surface and one
pure thermoplastic surface. Other temperatures and other solvents
can also be used to carry out this process, as well as other mold
materials and polymer components.
Example 20
[0246] In another example, a polyether urethane was swollen in 70%
acrylic acid with 0.1% 2-hydroxy-2-methyl propiophenone and 0.1%
methylene bisacrylamide. One side of the material was dabbed dry,
and then exposed to air and treated with UV light. The resulting
gradient semi-IPN was then washed in an aqueous salt solution to
neutralize the poly(acrylic acid), achieve equilibrium swelling,
and remove any unreacted monomers. In other experiments, the
material was exposed to nitrogen or argon during curing.
Example 21
[0247] In another example, a polyether urethane (Elasthane.TM. 55D)
was injection molded and then swollen in 70% acrylic acid with 0.1%
v/v 2-hydroxy-2-methyl propiophenone and 0.1% w/w methylene
bisacrylamide followed by UV-initiated crosslinking to yield a
fully interpenetrating polymer network of the polyether urethane
and poly(acrylic acid). The IPN was then washed in an aqueous salt
solution to neutralize the poly(acrylic acid), achieve equilibrium
swelling, and remove any unreacted monomers.
Example 22
[0248] In another example, a polyether urethane (Elasthane.TM. 75D)
was injection molded, dip-casted (solution casted) on one side in a
polyether urethane solution (Elasthane.TM. 55D in 25% DMAC) and
dried in a convection oven to remove the DMAC solvent. The dried
material was swollen in 70% acrylic acid with the 70% acrylic acid
with 0.1% v/v 2-hydroxy-2-methyl propiophenone and 0.1% w/w
methylene bisacrylamide followed by UV-initiated crosslinking to
yield a fully interpenetrating polymer network of the polyether
urethane and poly(acrylic acid). The IPN was then washed in an
aqueous salt solution to neutralize the poly(acrylic acid), achieve
equilibrium swelling, and remove any unreacted monomers.
Example 23
[0249] In another example, a polycarbonate urethane (Bionate 75D)
was injection molded, dip-casted (solution casted) on one side in a
polyether urethane solution (Elasthane.TM. 55D in 25% DMAC) and
dried in a convection oven to remove the DMAC solvent. The dried
material was swollen in 70% acrylic acid with 0.1% v/v
2-hydroxy-2-methyl propiophenone and 0.1% w/w methylene
bisacrylamide followed by UV-initiated crosslinking to yield a
fully interpenetrating polymer network of the polyether urethane
and poly(acrylic acid). The IPN was then washed in an aqueous salt
solution to neutralize the poly(acrylic acid), achieve equilibrium
swelling, and remove any unreacted monomers.
Example 24
[0250] In another example, a polyether urethane (Elasthane.TM. 75
D) was injection molded and then dip-casted (solution casted) in a
methacryloxy-functionalized polyether urethane solution
(Elasthane.TM. 55 D in 25% DMAC) along with the aforementioned
photoinitiator and then was exposed to UV light to crosslink the
methacryloxy-functionalized polyether urethane. The material was
then dried in a convection oven to remove the DMAC solvent. The
dried material was then swollen in 70% acrylic acid with the 0.1%
v/v 2-hydroxy-2-methyl propiophenone and 0.1% w/w methylene
bisacrylamide followed by UV-initiated crosslinking to yield a
fully interpenetrating polymer network of the polyether urethane
and poly(acrylic acid). The IPN was then washed in an aqueous salt
solution to neutralize the poly(acrylic acid), achieve equilibrium
swelling, and remove any unreacted monomers.
Example 25
[0251] In another example, a polycarbonate urethane (Bionate 75D)
was injection molded and then dip-casted (solution casted) in a
methacryloxy-functionalized polyether urethane solution
(Elasthane.TM. 55 D in 25% DMAC) and then was exposed to UV light
to crosslink the methacryloxy-functionalized polyether urethane.
The material was then dried in a convection oven to remove the DMAC
solvent. The dried material was then swollen in 70% acrylic acid
with the 0.1% v/v 2-hydroxy-2-methyl propiophenone and 0.1% v/v
triethylene glycol dimethacrylate followed by UV-initiated
crosslinking to yield a fully interpenetrating polymer network of
the polyether urethane and poly(acrylic acid). The IPN was then
washed in an aqueous salt solution to neutralize the poly(acrylic
acid), achieve equilibrium swelling, and remove any unreacted
monomers.
Example 26
[0252] In another example, a polyether urethane (Elasthane.TM. 55
D) solution casted and then swollen in 35% sulfopropyl methacrylate
in acetic acid with 0.1% v/v 2-hydroxy-2-methyl propiophenone and
0.1% w/w methylene bisacrylamide followed by UV-initiated
crosslinking to yield a fully interpenetrating polymer network of
the polyether urethane and poly(acrylic acid). The semi-IPN was
then washed with water to remove the acetic acid, and then in an
aqueous salt solution to neutralize the poly(acrylic acid), achieve
equilibrium swelling, and remove any unreacted monomers.
Example 27
[0253] In another example, a polyether urethane (Elasthane.TM. 55D)
solution casted and then swollen in 35% sulfopropyl methacrylate
and 35% acrylic acid in water with the 0.1% v/v 2-hydroxy-2-methyl
propiophenone and 0.1% w/w methylene bisacrylamide followed by
UV-initiated crosslinking to yield a fully interpenetrating polymer
network of the polyether urethane and poly(acrylic acid). The
semi-IPN was then washed in an aqueous salt solution to neutralize
the poly(acrylic acid)/poly(sulfopropyl methacrylate) copolymer,
achieve equilibrium swelling, and remove any unreacted
monomers.
Example 28
[0254] In another example, a rectangular sample of PMMA
(plexiglass) was swollen briefly in 100% acrylic acid in water with
the 0.1% v/v 2-hydroxy-2-methyl propiophenone and 0.1% w/w
methylene bisacrylamide followed by UV-initiated crosslinking to
yield a fully interpenetrating polymer network of the PMMA and
poly(acrylic acid). The IPN was then washed in an aqueous salt
solution to neutralize the poly(acrylic acid), achieve equilibrium
swelling, and remove any unreacted monomers.
Example 29
[0255] In another example, a rectangular specimen of polydimethyl
sulfoxide (PDMS, Sylgard.RTM. 184) was prepared according to the
manufacturer's specifications and then was swollen briefly in a 35%
acrylic acid solution in tetrahydrofuran along with 0.1% v/v
2-hydroxy-2-methyl propiophenone and 0.1% v/v triethylene glycol
dimethacrylate, followed by UV-initiated crosslinking to yield a
fully interpenetrating polymer network of the PDMS and poly(acrylic
acid). The IPN was washed in an aqueous salt solution to neutralize
the poly(acrylic acid), achieve equilibrium swelling, and remove
any unreacted monomers.
Example 30
[0256] FIG. 35 is a cross-section of a hydrated arthroplasty device
and shows that the arthroplasty device is, in effect, a synthetic
version of an osteochondral graft that emulates the structure,
elastic modulus, fracture strength, and lubricious surface of
natural cartilage on one side and the stiffness, strength, and
porosity of trabecular bone on the other side. The device is
comprised of a composite gradient material featuring a lubricious,
cartilage-like polymer that smoothly transitions into a stiff,
porous, bone-like anchoring surface. The gradient was designed to
mimic the compositional gradient inherent to natural joints, in
which compliant, slippery cartilage becomes progressively more hard
and bone-like from superficial to deep along the thickness
direction. In practice, this "biomimetic" gradient should yield a
physiologic stress distribution over the underlying bone while also
minimizing micromotion at the bone interface by effectively
matching the stiffnesses of the device and bone at their point of
contact. Suitable materials are described, e.g., in the following,
the disclosures of which are incorporated herein by reference: U.S.
Patent Appl. Ser. No. 61/079,060 (filed Jul. 8, 2008); U.S. Patent
Appl. Ser. No. 61/095,273 (filed Sep. 8, 2008); and U.S. patent
application Ser. No. 12/148,534 (filed Apr. 17, 2008).
Example 31
[0257] FIG. 36 shows contact angle analysis indicating that the
material of this invention is very hydrophilic. When a drop of
water is placed on a surface, the shape the drop takes is dependent
on the composition of the surface. A hydrophilic surface attracts
the water and creates a flatter drop, while a hydrophobic surface
repels the water and creates a rounder drop. The degree of
hydrophilicity of the surface is inferred by measuring the angle
created between the surface and the drop of water, referred to as
the contact angle. Typically, a more hydrophilic surface will have
a contact angle of about 0-45.degree. with water, while a more
hydrophobic surface will have a contact angle greater than
45.degree. with water.
[0258] The contact angle between the charged hydrogel IPN made by
this invention and water was determined. Briefly, a sheet of
Elasthane.TM. 55D (polyetherurethane) was soaked in acrylic acid
with initiator and cross-linker, and cured to form a semi-IPN
(PEU/PAA semi IPN). After curing, the charged PEU/PAA semi IPN was
hydrated in phosphate buffered saline. The material was removed
from the solution and its surface briefly dabbed to remove any
residual liquid. A drop of water was placed on the surface of the
material, and the contact angle read using a Goniometer. The
results showed a contact angle of approximately 80. For comparison,
readings taken on starting materials of solution-casted
polyurethanes and injection-molded polyurethane had contact angles
of approximately 72.degree. and 69.degree., respectively. This
result demonstrates that the incorporation of a poly(acrylic acid)
network into polyurethane according to the current invention
dramatically increases surface hydrophilicity.
Example 32
[0259] The differences in the structures of the charged hydrogel
IPN and polyurethane are shown by Transmission Electron Microscopy
(TEM). TEM creates a highly magnified image of a material. TEM was
performed on samples of polyetherurethane/poly(acrylic) acid semi
IPN (PEU/PAA semi IPN) of the current invention and of unmodified
polyetherurethane. Briefly, a sheet of Elasthane.TM. 55D
(polyetherurethane) was soaked in acrylic acid with initiator and
cross-linker, and cured. It was stained with osmium tetroxide per
standard procedures to perform TEM analysis. FIG. 37A shows a 34
k.times. magnification image of PEU while FIG. 37 B shows the
PEU/PAA semi-IPN. The sizes of light and dark regions,
corresponding to the amorphous (soft) and ordered (hard) domains,
are increased in the TEM images of the PEU/PAA semi-IPN relative to
the unmodified PEU. The PAA appears sequestered within the PEU soft
segments. on the basis of the larger domain sizes in the PEU/PAA
sample compared to the PEU sample, the degree of phase separation
is greater in the PEU/PAA sample compared to the unmodified
PEU.
Example 33
[0260] FIG. 38 shows a TEM of the same PEU/PAA semi-IPN material as
FIG. 37 at 12.4 kX magnification. The schematic illustrates how the
hard segments are phase separated from the soft segments of the
interpenetrated polymer network.
Example 34
[0261] FIG. 39 shows the static mechanical properties of the
PEU/PAA IPN which comprises an exemplary joint interface surface of
an orthopaedic implant. Uniaxial tensile tests were conducted to
determine the initial Young's modulus in tension, the
strain-at-break, and stress-at-break of the materials. Dog bone
specimens were tested according to ASTM D638, at a strain rate of
0.3%/sec. The average true stress-true strain curve for the
material of the joint interface material is presented in FIG. 40.
In the linear portion of the curve, the elastic modulus (as
provided from the true stress, true strain curve) is E=15.3 MPa
which is very close to the tensile properties reported for natural
cartilage. The ultimate true stress was found to be at
approximately .sigma..sub.ult=52 MPa at .epsilon..sub.ult=143% true
strain (of note, cartilage is found to fail at around 65% strain).
Strain hardening under tension was observed for true strains of 80%
and higher. The Poisson's ratio (equilibrium) was estimated by
measuring the lateral contraction of the dog bone neck region and
was found to be consistent along the strain range at .nu.=0.32. The
bulk modulus was therefore calculated from the equation
K=E/3(1-2.nu.) and was found to be 18.3 MPa. Unconfined compression
plug tests according to ASTM D695 reveal that PEU/PAA semi-IPN has
excellent compressive properties, with a compressive stiffness
modulus of 15.6 MPa (same as the tensile modulus, based on true
stress-strain) and a failure strength that is higher than 50
MPa.
Example 35
[0262] FIG. 40 shows the thermal curves of PEU and PEU/PAA semi-IPN
samples evaluated by Differential Scanning Calorimetry (DSC) at a
heating rate of 40.degree. C. per minute. FIG. 41 compares the
thermal transitions of PEU and PEU/PAA semi-IPN samples evaluated
by DSC at two different heating rates. The thermal transition
temperatures including the glass transition temperature T.sub.g,
the crystallization temperature, and the melting temperature Tm
were determined. Below its T.sub.g, the heat capacity of the
polymer is lower and the polymer is harder or glassier. Above the
T.sub.g, the heat capacity of the polymer increases and the polymer
becomes more flexible. Above this temperature, for some polymers is
the crystallization temperature and at least some of the domains of
the molecule become more organized, and essentially crystalline. At
a higher temperature is the melting temperature when the
crystalline portions completely melt. The procedure was done
following ASTM D3418-03 test method using a TA Instruments Q200 DSC
system with a Modulated Differential Scanning Calorimeter and
Refrigerated Cooling System (RCS90). Briefly, a sheet of
Elasthane.TM. 55D (polyetherurethane) was soaked in acrylic acid
with an initiator and cross-linker and then cured. A small amount
(2-6 mg) of PEU/PAA semi-IPN sample was placed into a first
aluminum pan. A cover was placed on the top of the pan and crimped
with a Universal Crimping press to sandwich the sample between pan
and cover. Heat was applied to the first pan and, separately, to a
reference pan, and the current flow to each was changed to keep the
temperatures of the two materials the same. The heat flow of the
material being tested was graphed against the temperature and the
slopes of the curves indicate the thermal transition temperatures
(FIG. 40). Several tests were performed, using different rates of
heating (10.degree. C. and 40.degree. C. per minute). By performing
the tests at different rates of heating, different resolution is
obtained for the thermal transitions, as seen in FIG. 41. Because
the T.sub.g can depend on the previous thermal history of the
material, the material is subjected to two heat cycles. The first
heat cycle is used to standardize the conditions under which the
polymer arrives at its test state, and the second test cycle is
used to generate transition temperatures. The glass transition
temperatures, T.sub.g for both the PEU/PAA semi IPN and the PEU
were around 21.degree. C. when the rate of heating was kept at
10.degree. C. per minute. The crystallization and melting
temperatures were lower in the PEU/PAA compared with the PEU. At a
heating rate of 40.degree. C. per minute, the crystallization
temperatures were 90.degree. C. for the PEU/PAA compared with
93.degree. C. for the PEU. When the heating rate was slowed to
10.degree. C. per minute, the crystallization temperatures observed
were 79.degree. C. for the PEU/PAA compared with 92.degree. C. for
the PEU. Finally, at a heating rate of 40.degree. C. per minute,
the Tm temperatures were 164.degree. C. for the PEU/PAA compared
with 178.degree. C. for the PEU. When the heating rate was slowed
to 10.degree. C. per minute, the T.sub.m temperatures observed were
154.degree. C. for the PEU/PAA with 176 and 186.degree. C. for the
PEU. In some analyses of the PEU, two T.sub.m's were observed
(176.degree. C. and 186.degree. C.), which may be due to different
segments in the polymer. The change of the T.sub.m is due at least
in part to an increase in polymer volume caused by the addition of
the PAA, leading to fewer hard segments per volume of polymer.
Example 36
[0263] The coefficient of friction .mu. of a PEU/PAA semi-IPN of
this invention against itself was measured real-time during a wear
test using a built-in torque cell, and was found to range between
0.015 to 0.06, and as shown in FIG. 42, is similar to
cartilage-on-cartilage .mu. values. Because of its lower (compared
to cartilage) permeability, the PEU/PAA semi-IPN of this invention
can preserve a lower coefficient of friction for longer and at
higher contact pressures. FIG. 42 shows the effective coefficient
of friction during a wear test of the joint interface material
(labeled "PEU/PAA-on-PEU/PAA" in the graph) under 2.4 MPa of
continuous (static) contact pressure. Literature reports on natural
cartilage values and experimental data/literature reports on UHMWPE
on CoCr are also presented in the plot (Mow, 2005; Wright 1982). As
expected, the coefficient of friction was found to remain unchanged
over the course of time when the load was applied in cycles of 1
Hz; similar results are reported for cartilage. The low coefficient
of friction in the material can be explained in terms of (a)
hydroplaning action, (b) load sharing between the solid and the
fluid phases of the material (c) thin film lubrication as water
persists on the surface of the material. The small increase of .mu.
under static load can be explained by a small partial dehydration
of the material under the pressure. In comparison, natural
cartilage will lose most of its water under static load and
therefore its coefficient of friction increases rapidly and to
higher levels. Removal of the load and subsequent rehydration
restores the initial coefficient of friction for natural
cartilage.
Example 37
[0264] The coefficient of friction is a number that indicates the
force resisting lateral motion of an object. It is expressed as a
unitless ratio of the frictional force to the normal force. The
dynamic coefficient of friction for the polyether
urethane/polyacrylic acid (PEU/PAA) semi-IPN on was tested on
metal, and the dynamic coefficient of friction is shown as a
function of time. Briefly, a piece of Elasthane.TM. 55D
(polyetherurethane) was soaked in acrylic acid with an initiator
and cross-linker, and cured to form a water swellable semi-IPN of
the present invention. Plugs 8.8 mm in diameter and 1 mm thick were
cut, swollen in PBS, and then rotated at a frequency of 1 Hz
against a 3/16'' stainless steel disc at a contact stress of 2.0
MPa while being submerged in PBS. Using a custom-made wear tester
made according to ASTM F732 standards equipped with both a force
load cell and a torque load cell, the dynamic coefficient of
friction was measured real-time during the wear test experiment.
The dynamic coefficient of friction of the material varied between
0.005 and 0.015 over a period of 36 hours.
Example 38
[0265] Wear experiments of the PEU/PAA semi-IPN of this invention
were conducted according to ASTM F732 using a pin-on-disc
configuration. Results are shown in FIGS. 44, 45, and 45. Discs and
pins formed from the joint interface material were tested to
2,500,000 cycles. As a basis for comparison to industry standard
materials, a CoCr pin-on-UHMWPE (Cobalt chrome on ultra-high
molecular weight polyethylene) disc configuration was also tested
for 1,000,000 cycles.
[0266] In the test of the PEU/PAA semi IPN of this invention, the
pins were 8.8 mm in diameter, 2.5 mm in thickness. The disc was 88
mm in diameter and 2.5 mm in thickness. The pins were rotated over
the disc at a radius of 24 mm and at a rate of 1.33 Hz under a
pneumatically applied cyclic load. A pressure regulator was used to
adjust the air pressure so that the desired force was applied. The
load was measured using a load cell (Sensotec Honeywell, Calif.)
directly under the disc. The disc and the pins were mechanically
isolated so that the torque caused by the friction generated
between them can be measured by a torque cell (Transducer
Techniques, CA) connected to a computer equipped with a data
acquisition card (National Instruments, TX). The pin and discs were
contained in a chamber filled with PBS. The temperature was
controlled and kept constant at 37.degree. C. using a
thermocouple-resistor-fan system. Using the equation .mu.=T/r*F,
where T is the measured torque, r is the radius of rotation (=24
mm) and F being the total force applied on the pins, the
coefficient of friction was constantly monitored. The coefficient
of friction was found to be 0.016 and independent of the contact
pressure (range tested 0.1-3.5 MPa) and slightly increased to 0.021
under heavy static contact load, but returned to the original value
after fluid recovery. The wear was measured using the gravimetric
method every million cycles: the disc and the pins were weighed
separately after vacuum drying for 3 days. The wear test solution
(PBS) was collected and visually examined; no signs of visible wear
particles were noted at all steps of the tests. The wear test PBS
solution was vacuum filtered using a 2.5 .mu.m pore filter to
capture any wear particles, flushed with deionized water to remove
remaining PBS salts and then dried overnight under vacuum and
desiccant. As a control, a similar test was performed using CoCr
pins (Fort Wayne Metals, IN) on UHMWPE (Orthoplastics, UK). Three
polished (Ra<1.6 .mu.m) CoCr flat pins of OD=7 mm were tested in
the same instrument against a polished UHMWPE disc of 2.5 mm
thickness and OD=88 mm (rotation radius=24 mm), rotating at 1.2 Hz
under 3.4 MPa static contact load and at 37.degree. C. isolated
environment.
[0267] Observation of the disc formed from the PEU/PAA semi-IPN of
this invention after the test (FIG. 44A) revealed no
macroscopically perceptible wear track along the pin-on-disc
articulation surface. (FIG. 44B is a close-up view of the location
of the wear track. Dashed lines have been added to indicate the
path; the radial arrows start from the center of the disc.) In
comparison, as shown in FIG. 44C, the UHMWPE disc after 2.0 M
cycles of wear against CoCr pins has a visible track 126 .mu.m
deep.
[0268] Weighing of the wear test solution filtrate using a scale
with a 0.01 mg resolution (Mettler Toledo, Ohio) showed that the
volumetric wear rate of the PEU/PAA semi-IPN was approximately 0.6
mg/10.sup.6 cycles or 0.63 mm.sup.3/106 cycles or 0.63
mm.sup.3/150.times.10.sup.3 m. This value, however is close to the
resolution of the methods. A schematic of the wear test solution
from the wear test of the inventive joint interface material
comprised of PEU/PAA semi-IPN is shown in FIG. 45 A, demonstrating
an absence of particles in the PBS solution. Compare FIG. 45 A to
schematics of the wear test solution of the UHMWPE disc shown in
FIGS. 45 B and 45 C, which show substantial wear debris particles
generated during the CoCr-on-UHMWPE wear test.
[0269] Although attention was paid to eliminate external factors
such as dust, moisture and static in order to increase the accuracy
of the results, the wear values are well near the statistical and
practical detection limits of the methods available. These results
are consistent with the hypothesis that since the PEU/PAA semi IPN
according to the present invention--like natural cartilage-is
comprised of mostly water, and the surface is persistently
lubricated with a film of water, there is little, if any, contact
between solid matrices.
[0270] Wear particle measurements were also taken for the
CoCr-on-UHMWPE experiments, which not only created a visible wear
track (FIG. 44B) on the UHMWPE disc, but generated substantial
macroscopic wear debris (FIGS. 45B and C). The UHMWPE disc was
weighed and the difference in weight yielded an average wear rate
of 64 mg/10.sup.6 cycles or 69 mm.sup.3/150.times.10.sup.3 m (FIG.
46). This study points that the joint interface material of this
invention (labeled "PEU/PAA-on-PEU/PAA") is at least more than 100
more resistant to wear than the traditional combination of
CoCr-UHMWPE, widely used in total joint replacements.
Example 39
[0271] FIG. 47 shows the swelling behavior of PEU/PAA and PEU in
various aqueous and organic solvents. Briefly, a sheet of
Elasthane.TM. 55D (polyether urethane) was soaked in acrylic acid
with initiator and cross-linker, and cured to form a semi IPN. A
small piece of the IPN or Elasthane.TM.55D was obtained and
weighed. The sample was soaked for 20 hours in a solution
containing the solvent indicated in the Figure. (The samples were
swollen, but did not dissolve). The sample was removed from the
solvent, briefly dabbed dry, and then weighed again. The change in
weight due to swelling is expressed as the % difference. While
Elasthane.TM. 55D on its own does not take up water, the IPN of the
present invention readily swells with water to form a lubricious,
hydrated IPN. In addition, other solvents can be used to swell the
starting polymer to create the IPN of the current invention. In the
case of polyurethanes, the ability of various solvents to swell the
material depends on the properties of the solvent (such as its
polarity, acidity, and molecular weight) as well as the relative
solubility of the polymer components (e.g. hard and soft segments)
in the solvent.
Example 40
[0272] The swelling of polyetherurethane by acrylic acid in water
and acetic acid was tested. Swelling solutions were prepared
containing 10, 30, 50, and 70% acrylic acid monomer in deionized
water (FIG. 48A) and in acetic acid (FIG. 48B). Small pieces of
Elasthane.TM. .RTM. 55D (polyetherurethane) were obtained and
measured. A sample of the Elasthane.TM. was placed in each
solution. The samples were removed from the solvent, the surface
briefly dabbed dry, and then measured again. The change due to
swelling is expressed as the final length of the specimen after
equilibrium swelling (L.sub.f) divided by the original length
(L.sub.o) minus 1; in this way, the fractional increase in length
relative to the initial state (y=0) is plotted versus time.
Swelling of the Elasthane.TM. 55D was observed using either water
or acetic acid as a solvent. More swelling was observed when a
higher amount of acrylic acid was used in the swelling solution. Of
note, the concentration dependence of acrylic acid on the swelling
of the Elasthane.TM. samples was different depending on whether
water or acetic acid was used as the solvent.
Example 41
[0273] FIG. 49 shows the amount of poly(acrylic acid) present in
the PEU/PAA semi-IPN after curing is plotted as a function of the
starting concentration of acrylic acid monomer in different
swelling solutions.
[0274] Swelling solutions were prepared containing 10, 30, 50, and
70% acrylic acid monomer in deionized water and in acetic acid.
Small pieces of Elasthane.TM. 55D (polyetherurethane) were obtained
and weighed. Samples were placed in each of the water/acrylic acid
or acetic acid/acrylic acid solutions along with cross-linker and
initiator. The samples were cured, swollen in acrylic acid in
either water or acetic acid, removed from the solution, dried, and
then weighed again. Incorporation of acrylic acid into the
Elasthane.TM. 55D to form a semi-IPN was observed using either
water or acetic acid as solvent. More incorporation of acrylic acid
was observed when a higher concentration of acrylic acid was
present in the swelling solution.
Example 42
[0275] Semi IPNs were prepared essentially as described in FIG. 49,
and the polyacrylic acid content of the IPNs was determined. The
dried materials were weighed, swollen in saline until equilibrium
was reached, and weighed again. The change in weight of the semi
IPN is expressed as a ratio of the weight of the swollen
material/weight of the dry material (Ws/Wd) for each concentration
of polyacrylic acid. An increased amount of polyacrylic acid in the
polymer correlates with an increased uptake of saline into the
water-swellable semi-IPN. Since the semi-IPNs in these experiments
were neutralized to pH 7.4, in these experiments, the dry weight of
the semi-IPN included the salts present in the saline swelling
solution, since the monovalent cations (predominantly sodium, which
has a MW of 23 g/mol) are counterions to the carboxylate groups in
the material.
Example 43
[0276] FIGS. 51-54 show the results of creep and stress
relaxation/compression testing. Tests were performed on PEU/PAA
semi IPNs formed from Elasthane.TM. 55D (polyetherurethane) soaked
in acrylic acid with initiator and cross-linker, and cured.
[0277] FIG. 51 shows the results of cyclic compression testing. The
behavior of the PEU/PAA semi IPN was tested under dynamic
compression conditions to determine permanent creep and creep
recovery. Permanent creep is the time-dependent deformation of a
material under a constant load. Creep recovery measures the rate of
decrease in the applied deformation after a load is removed.
Experimental setup of the compression test followed the ASTM
standard D695, Standard Test Method for Compressive Properties of
Rigid Plastics, with the samples being subjected to a sinusoidal
loading scheme designed to mimic the physiologic, cyclic
compressive loads seen in a gait cycle.
[0278] A sample of the PEU/PAA semi IPN was removed and measured in
the direction of its thickness, subject to cycles of compressive
stress from 0-3 MPa at a frequency of 1 Hz for over 60,000 cycles,
measured again in the direction of its thickness, re-equilibrated
(relaxed) in PBS to allow for recovery from creep, and measured
again in the direction of its thickness. FIG. 51 A shows the
results of thickness measurements on representative samples subject
to one-second long cycles of tests (at the 1st, 1000th, 10,000th,
20,000.sup.th, 40,000.sup.th, and 60,000.sup.th cycles)
superimposed in one figure. FIG. 51 B shows how the thickness of
the material changes over all cycles of testing. The thickness of
the material, as measured after load was removed during the cycle,
dropped from an initial value of 2.160 mm at the first cycle to
about 2.000 mm by the 60,000.sup.th cycle. However, after
re-equilibration (relaxation) in PBS and creep recovery at the last
cycle, the material returned to a thickness of 2.135 mm, a total
loss of thickness of only 1.1% due to permanent creep.
[0279] FIG. 52 presents the equilibrium compressive behavior of the
PEU/PAA semi IPN as determined through a multiple-step stress
relaxation test, in which a given displacement is applied and then
the material is allowed to relax (equilibrate). Notably, under
these test conditions, the material fully recovered to its
equilibrium value after removal of the load, as shown by the last
data point in FIG. 52, indicating full creep recovery. The stress
of 2.20 MPa (4th data point) is 15% higher than the maximum
functional stress in a hip device (total load through the hip of 3
times body weight) that is predicted by finite element models.
[0280] A static creep test was also performed (data not shown).
Creep is the time-dependent deformation of a material under a
constant load. The behavior of the PEU/PAA semi IPN tested under
static compression was tested following ASTM D2290-01 "Standard
Test Methods for Tensile, Compressive, and Flexural Creep and
Creep-Rupture of Plastics". A plug of the PEU/PAA semi IPN with an
initial diameter of 9.525 mm and a thickness of 1.115 mm was put
under an initial stress 4 MPa in a fluid PBS bath. After applying
the stress for approximately 20,000 seconds (to a total strain of
14.29%), the load was released and the material allowed to relax
(re-equilibrate) in PBS. The final thickness of the plug was 1.109
mm. The final unrecovered creep after more than 40,000 cycles was
2.7%.
[0281] FIG. 53 shows the results of a compression set test
according to ASTM D395. In this test, a plug of PEU/PAA with an
initial diameter of 9.525 mm and a thickness of 2.13 mm was
subjected to a constant compressive strain of 15% for 23 hours at
room temperature in a fluid bath filled with PBS. After allowing
the material to relax and re-equilibrate in PBS, the final
thickness of the plug was 2.08 mm. This yields a compression set
value of 9.5%. As a basis of comparison, PEU (Elasthane.TM. 55D)
alone exhibits a compression set value of about 45% under the same
conditions (22 hrs, room temperature). Therefore, the presence of
the polyelectrolyte in the PEU/PAA semi-IPN provides a way for the
PEU material to resist permanent creep through rehydration of the
matrix with water due to the hydrophilicity and high swellability
of the negatively charged polyelectrolyte.
Example 44
[0282] FIG. 54 shows a list of some of the materials made in
accordance with the present invention. The first column shows the
hydrophobic polymer used. If a modification was made to the
hydrophobic polymer as indicated in the second column, the material
for the modification was cast with the material, or, if the
modification was crosslinking functionality, the modification was
added and the material prepared and crosslinked and used thereafter
with the crosslinks reacted. The monomer, comonomer (if any),
crosslinker and initiator were added in the indicated solvent as
indicated in the figure in order to swell the prepared hydrophobic
polymer. Each hydrophobic polymer sample was allowed to swell for
up to 2 days, removed from the solution, and cured using the
indicated method following standard procedures. The material was
washed and swollen in PBS. The abbreviations used are as follows:
MBAA=methylene bisacrylamide, HMPP=2-hydroxy-2-methyl
propiophenone, TEGDMA=triethylene glycol dimethacrylate, and
H.sub.20=water.
Example 45
[0283] FIG. 69 shows a porous bone-interface material that can be
placed on a surface of a device such as an osteochrondral plug to
facilitate bone ingrowth. The osteochrondral plug shown is a
polycarbonate urethane material with a shore hardness of 75D and a
compressive modulus of 2.2 GPa. To form the porous bone-interface
material shown in FIG. 69, polyurethane beads
((size.apprxeq.700-1300 .mu.m) were manufactured. Porous cylinders
(porosity=20-30%; pore size: 100-400 m) were then created from the
beads by heat-sintering them together. Compressive mechanical
testing of the porous cylinders showed a modulus of 100-150 MPa,
depending on the material porosity (see FIG. 71).
[0284] The bone-interface material of FIG. 69 was also found to be
osteoconductive, i.e. support bone formation directly on the
material surface. An osteoconductive material will facilitate
calcium-phosphate (CaP) formation on the material surface when
incubated in Simulated Body Fluid (SBF). To test osteoconductivity,
the porous bone-interface cylinders were incubated in 1.5.times.SBF
for 20 days. Alizarin red staining shows widespread deposition of
CaP on the material surface (see FIG. 70), indicating the
osteoconductivity of the bone-interface material.
[0285] An additional embodiment of the present invention takes
advantage of the high mechanical strength of hydrophobic thermoset
or thermoplastic polymers high mechanical strength of hydrophobic
thermset or thermoplastic polymers and combines those materials
with certain non-ionic polymers as a useful way to achieve
increased mechanical strength with greater adhesiveness. Because of
their mechanical strength, it has been desirable to use hydrophobic
thermoset or thermoplastic polymer containing materials in load
bearing or structural support components for a variety of purposes.
For example, as discussed above, hydrophobic thermoset or
thermoplastic polymers such as polyurethane can be formed into
medical implants such as those used for joint arthroplasty.
[0286] This use, however, is often limited by the ability to
securely attach the hydrophobic thermoset or thermoplastic polymer
containing materials to a destined location or substrate. For
example, a femoral head cap implant for hip replacement must be
fixed to a patient's femoral head in the hip joint. To ensure
patient safety and proper operation of the implant, the implant
must be properly adhered to the surface of the femoral head.
[0287] In cases with high stiffness devices such as cobalt chrome,
titanium, or hard plastic-ultra-high-molecular-weight polyethylene
(UHMWPE), bone cements have been used as bonding/adhesive agents to
fix these devices to bone. Such bone cements generally fill the
meeting spaces between and on the surfaces of the device and the
bone, thereby fixing the device to the bone. However, with more
compliant materials that can be made from hydrophobic thermoset or
thermoplastic polymers (such as polyurethane), the mechanical
strength of the material and the adhesiveness between the bone
cement and the implant is of particular importance in that
compliant materials may conform their shapes under load.
[0288] For example, failure to provide adequate adhesion could
result in sliding, dislodgement, loosening, and general movement of
the implant from its proper placement. Such movement can cause
pain, weaken and render the implant inoperable, and require
corrective surgeries.
[0289] Various formulations and developments of cements, adhesives,
fillers, bonding agents, and mechanical fixation components such as
mating pegs, screws, and grooves have been suggested to address
this concern. However, these approaches focus on the bonding agents
or the mechanical attachment components rather than on the
composition and characteristics of the compliant materials
containing hydrophobic thermoset or thermoplastic polymers. One
embodiment of this invention introduces materials and articles that
comprise IPNs or semi-IPNs which exhibit strong adhesion with other
materials such as orthopaedic anchoring compounds while also
providing high mechanical strength or stiffness. The terms
interlocking agent, grouting agent, anchoring compound, adhesive
agent, and/or bonding agent refer broadly and interchangeably to
materials that are capable of binding, fusing, adhering, filling,
cementing, affixing, or otherwise attaching one material, article,
object, component etc. to another.
[0290] As discussed previously, hydrophobic thermoset or
thermoplastic polymers can be infused with various monomers that
are polymerized to form an IPN or a semi-IPN. In some instances,
the IPN or semi-IPN can extend throughout the bulk of the material
or throughout only a portion of the material, e.g. a particular
region or in a gradient. Depending on the selection of the monomer,
the resulting IPN or semi-IPN can exhibit a variety of properties
(e.g. stiffness, lubriciousness, strength, conductivity, etc.) and
variability of range within each property.
[0291] The property or properties imparted depend on several
factors including, but not limited to, the monomer(s) selected, the
degree of monomer penetration into the hydrophobic thermoset or
thermoplastic polymers prior to monomer polymerization, the grade
of the hydrophobic thermoset or thermoplastic polymers, whether the
hydrophobic thermoset or thermoplastic polymers are
phase-separated, whether the monomer penetration is in a single
region or multiple portions of the hydrophobic thermoset or
thermoplastic polymers etc.
[0292] As discussed above, FIGS. 1A-C illustrate the process with
respect to a thermoplastic polyurethane-based polymer containing a
network of hard segments 10 (shown as open rectangles) and soft
segments 12 (shown as lines). In FIG. 1B, the soft segments 12 are
swollen with ethylenically unsaturated monomers with or without
ionizable functional groups such as vinyl-based monomer 14 (shown
as circles) and optional solvent, along with an initiator and
cross-linker (not shown), while mostly not affecting the hard
segment material. This swelling process is not dissolution of the
polymer; the hard segments act as physical crosslinks to hold the
material together as the soft segments are imbibed with the
monomer(s) and optional solvent(s). After polymerization and
cross-linking of the monomers, a second network 16 (shown as dark
lines in FIG. 1C) is formed in the presence of the first network to
create an IPN in which the second polymer (i.e., the polymerized
monomer) is primarily sequestered within the soft, amorphous domain
of the first polymer. Despite some degree of molecular
rearrangement and further phase separation, the hard segments
largely remain ordered and crystalline, providing structure and
strength to the material.
[0293] The new properties provided by this IPN depend on the
properties of the polymerized monomers that were introduced and on
any optional post-polymerization processing. Examples of such new
properties include lubriciousness, conductivity, hardness,
absorbency, permeability, photoreactivity and thermal reactivity.
In some embodiments, an adhesiveness property can be achieved by
introducing a non-ionic polymer into hydrophobic thermoset or
thermoplastic polymers to form an IPN or semi-IPN. In these
embodiments, the non-ionic polymer can be selected based on the
presence of the non-ionic polymer in the material to be adhered to
the IPN or semi-IPN.
[0294] By way of example, in some embodiments, a material
containing polyurethane may be destined for use as a joint implant
that will be attached to a bone's surface with bone cement. The
majority of load bearing orthopaedic bone cements comprise
non-ionic polymers derived from ethylenically unsaturated monomers
without ionizable functional groups, like methyl methacrylate (MMA)
and styrene, or combinations thereof. Many commercially available
bone cements contain a polymethylmethacrylate (PMMA) polymer or
copolymer.
[0295] Typically, for PMMA bone cements, MMA monomers are initially
present in a liquid state prior to bonding. To activate the bone
cement, the MMA is cured (polymerized) in situ to act like a grout
or filler that interdigitates with the bone trabecular space and
the features of the device to be implanted. This forms an interlock
between the device, PMMA bone cement, and the bone that secures
device fixation.
[0296] For materials containing hydrophobic thermoset or
thermoplastic polymers, bonding through interdigitation can be
complemented by adhesion between an IPN or semi-IPN in the material
and the bonding agent. Where a PMMA bone cement is used, PMMA can
be employed as the non-ionic polymer component of a IPN or semi-IPN
with hydrophobic thermoset or thermoplastic polymers. MMA monomers
can be introduced by infusion/diffusion into the hydrophobic
thermoset or thermoplastic polymers and polymerized to form an IPN
or semi-IPN within the starting material. Once formed, the PMMA in
the IPN or semi-IPN is fused and compositionally continuous with
the PMMA in the bone cement.
[0297] Without being bound to any theory, it is believed that the
non-ionic polymer present in the bonding agent (e.g. as a
constituent/ingredient) fuses to the non-ionic polymer phase of the
IPN or semi-IPN, thereby providing actual adhesion between the
bonding agent and the material containing the IPN. It is further
believed that adding one or more layer(s) of the bonding agent to
the IPN will result in strong adhesion between the IPN containing
material and the bonding agent, which serves to facilitate a strong
adhesion between the IPN containing material and a destination
location (e.g. bone surface).
[0298] FIG. 55 is a photograph illustrating one embodiment where an
orthopaedic PMMA bone cement (Stryker Simplex) 800 was cured
(according to the company's directions) on a PMMA-polyurethane-IPN
802. To form the PMMA-polyurethane-IPN 802, the original
polyurethane plate was infused by swelling a polyurethane plate
with MMA. Subsequently, the MMA was polymerized to PMMA inside the
polyurethane. PMMA bone cement was then applied to the IPN 802 to
form layer 800.
[0299] Stiffness, adhesion, and shear strength tests were conducted
on the resulting PMMA-polyurethane-IPN 802. Test results show that
the PMMA-polyurethane-IPN exhibited increased stiffness, greater
adhesiveness, and greater shear strength compared to the original
polyurethane plate without the IPN.
[0300] With regard to stiffness, compressive tests in a universal
testing machine revealed that an Elasthane.TM. 55D plug of OD=10 mm
and 4 mm thickness had a stiffness modulus of 80 MPa whereas after
the formation of a PMMA-polyurethane-IPN (at 70%-30% proportions)
the stiffness modulus increase to approximately 1.5 GPa.
[0301] Although a commercially available polyurethane product,
Elasthane, Bionate, Pursil, or Sylgard was used in some examples as
a hydrophobic thermoset/thermoplastic polymer, it is understood in
the art that any suitable hydrophobic thermoset/thermoplastic
polymer may be used and there is no limitation as to the particular
commercial products/tradenames described herein.
[0302] FIGS. 56A-B show the shear strength properties of the
PMMA-polyurethane-IPN compared to the original polyurethane
material. The adhesion between the PMMA-polyurethane-IPN and the
PMMA cement was tested using a universal mechanical testing
machine. As shown in FIG. 56A, shear tests of the
PMMA-polyurethane-IPN with a PMMA cement layer demonstrated average
shear strength of 1.35 MPa, which far exceeds the requirements for
a total hip replacement system. In comparison, as shown in FIG.
56B, the shear strength of the polyurethane alone with a PMMA
cement layer was approximately 0.25 MPa. This data indicates that
use of the PMMA-polyurethane IPN increased the stiffness of the
starting material while also improving the adhesion between the
starting material and the PMMA cement.
[0303] Although the examples above illustrate the use of the MMA
monomer to form a PMMA-polyurethane-IPN, it can appreciated that
any number of suitable monomers can be used to form an IPN or
semi-IPN which imparts properties such as stiffness, strength, or
adhesiveness to a thermoset/thermoplastic polymer starting
material. This can be understood more generally as an IPN or a
semi-IPN formed in a material containing a hydrophobic thermoset or
thermoplastic polymer T by introducing a monomer P' into thermoset
or thermoplastic polymer T, which is then polymerized from monomer
P' to penetrating polymer P.
[0304] In other embodiments, an exemplary list of monomer P'
suitable for this process include any number or combinations of
ethylenically unsaturated monomers that are not ionizable, i.e. do
not have chemical groups that can bear positive or negative charge
such as (but not limited to) methyl acrylate, methyl methacrylate,
hydroxyethyl acrylate/methacrylate, and styrene. In further
embodiments, suitable non-ionic polymers P include
polymethylmethacrylate, polystyrene, or a PMMA-polystyrene
copolymer.
[0305] In further embodiments an exemplary list of hydrophobic
polymers modifiable by the process of this invention includes the
following: Acrylonitrile butadiene styrene (ABS),
Polymethylmethacrylate (PMMA), Acrylic, Celluloid, Cellulose
acetate, Ethylene-Vinyl Acetate (EVA), Ethylene vinyl alcohol
(EVAL), Kydex, a trademarked acrylic/PVC alloy, Liquid Crystal
Polymer (LCP), Polyacetal (POM or Acetal), Polyacrylates (Acrylic),
Polyacrylonitrile (PAN or Acrylonitrile), Polyamide (PA or Nylon),
Polyamide-imide (PAI), Polyaryletherketone (PAEK or Ketone),
Polyhydroxyalkanoates (PHAs), Polyketone (PK), Polyester,
Polyetheretherketone (PEEK), Polyetherimide (PEI), Polyethersulfone
(PES)-- see Polysulfone, Polyethylenechlorinates (PEC), Polyimide
(PI), Polymethylpentene (PMP), Polyphenylene oxide (PPO),
Polyphenylene sulfide (PPS), Polyphthalamide (PPA), Polystyrene
(PS), Polysulfone (PSU), Polyvinyl acetate (PVA), Polyvinyl
chloride (PVC), Polyvinylidene chloride (PVDC), Spectralon,
Styrene-acrylonitrile (SAN), Polydimethylsiloxane (PDMS), and
Polyurethanes (PU).
[0306] As discussed, to impart adhesiveness, any number or
combination of hydrophobic thermoset or thermoplastic polymers and
non-ionic polymers can be employed to form a suitable IPN or
semi-IPN. In some instances, the non-ionic polymer P for forming
the IPN or semi-IPN is selected based on its presence as an
ingredient or constituent in a material to be adhered to by the IPN
or semi-IPN (i.e. the material also contains some amount of
non-ionic polymer P.) In other alternative embodiments, the
non-ionic polymer P is selected based on its affinity to the
material where the non-ionic polymer P may not be a constituent of
the material. For example, non-ionic polymer P may exhibit affinity
to other constituents present in a bonding agent. The formulation
of a commercially available bone cement is provided below as an
example of non-ionic polymer components present in an anchoring
material that can be used to form an IPN:
TABLE-US-00002 Stryker Simplex P: Liquid component (20 mL): Methyl
methacrylate (monomer) 97.4% v/v N.N-dimethyl-p-toluidine 2.6% v/v
Hydroquinone 75 .+-. 15 ppm Powder component (40 g): Polymethyl
methacrylate 15.0% w/w Methyl methacrylate - styrene - copolymer
75.0% w/w (contains 1.7% Benzoyl Peroxide) Barium sulfate, U.S.P.
10.0% w/w
[0307] Additionally, in some embodiments, the adhesive force
between an anchoring compound or bonding material and a hydrophobic
thermoset or thermoplastic-non-ionic polymer-IPN device can be
increased by adding roughness (micron-to-millimeter level) to the
device or/and by adding anchoring features such as grooves, pegs,
protrusions, recessions, etc. The roughness or the features can
added to the device by construction (during for example injection
molding) or at a later stage by addition (gluing, solution casting,
etc.)
[0308] Moreover, the IPN can incorporate either chemically or
physically within its bulk or its surface certain additives such as
antioxidants (e.g., Vitamin C, Vitamin E, Irganox.RTM., or
santowhite powder) and/or anti-microbial agents (e.g.,
antibiotics). These can be chemically linked to the material by,
for example, esterification of the anti-oxidant with any
vinyl-group containing monomer such as methacrylate, acrylate,
acrylamide, vinyl, or allyl ether.
[0309] Another aspect of this invention provides a process for
preparing the IPN or semi-IPNs as described. As discussed above, a
process of preparing an IPN or a semi-IPN includes placing a
monomer solution in contact with a hydrophobic thermoset or
thermoplastic polymer, diffusing the monomer solution into the
thermoset or thermoplastic polymer; and polymerizing the monomers
to form a polymer within the thermoset or thermoplastic polymer,
which results in an IPN or semi-IPN. As also described above,
selection of the monomer(s) or thermoset or thermoplastic polymer
and/or the conditions of each part of the process can affect the
properties of the resulting IPN/semi-IPN.
[0310] To form an adhesive IPN/semi-IPN with non-ionic polymer P, a
non-ionizable monomer P' solution can be placed in contact with a
solid form of a hydrophobic thermoset or thermoplastic polymer T.
The non-ionizable monomer P' solution is allowed to infiltrate and
penetrate through the thermoset or thermoplastic polymer T. Once a
suitable degree of penetration occurs, the monomer P' is
polymerized in the thermoset or thermoplastic polymer T to form an
IPN/semi-IPN that has an adhesiveness property when the non-ionic
polymer P phase in the IPN/semi-IPN is brought into contact with a
bonding agent containing the same non-ionic polymer P.
[0311] Polymerization can be accomplished by dissolving 1% (w/w)
2-hydroxy-2-methylpropiophenone photoinitiator in an MMA solution,
swelling the polyurethane with the MMA/photoinitiator solution, and
shining UV light at 2 mW/cm.sup.2 for 10 minutes onto the swollen
polyurethane. However, any number of photoinitiators and
concentrations thereof can also be used depending on their
solubility with the precursor solutions/materials.
[0312] Penetration of the monomer P' into the starting material can
be carried out by submersing and swelling the entire material or
piece with a monomer solution for a predetermined amount of time.
Alternatively, the swelling can be done by partially exposing the
material to a monomer solution, thereby reaching a partial or one
side treatment. Depending on the swelling time and/or factors, a
desired degree of treatment can be achieved on regions of the
material. For example, in some embodiments, the monomer P' infusion
occurs by submerging the entire thermoset or thermoplastic polymer
T solid form in the monomer P' solution. In further embodiments, a
section or region of the thermoset or thermoplastic polymer T solid
form is exposed to the monomer P' solution without fully immersing
the solid form in the solution. In further embodiments, the
entirety of the thermoset or thermoplastic polymer T may ultimately
be placed in contact with the monomer P' solution; however, the
exposure process may include iterative contacts to various regions
of the solid form to ultimately expose the entire solid form to the
monomer P' solution.
[0313] As shown in FIGS. 57A-D a swelling kinetics study was
performed on two commercial medical hardness grades of
polyurethane, Elasthane.TM. 55D and Elasthane.TM. 75D. In one
study, a disk of Elasthane.TM. 75D was submerged in a MMA solution
for about 150 hours. In a second study, disk of Elasthane.TM. 55D
submerged in MMA solution past 80 hours. The degree of swelling
accomplished for each grade is indicated by the weight percentage
change of the disks at various time points. FIGS. 57B and 57D
demonstrate the logarithmic relationship of the swelling
process.
[0314] As can be appreciated in the art, the terms "entire" or
"entirety" is not limited to all available surface area or volume
of the solid form. Rather, the terms broadly refer to the points,
area, volume, etc. that may be available for contact or exposure by
the solution. For example, in some embodiments, the available
exposure space on a solid form capable of forming an IPN/semi-IPN
may be less than the full surface area or volume provided by the
dimensions of the solid form.
[0315] In further embodiments, where the IPN/semi-IPN need only be
present in a portion, side, quadrant, or region of the solid form,
one or more section(s) of the thermoset or thermoplastic polymer
can be selectively exposed to the monomer P' solution. For example,
in the case of a joint implant made with a thermoset or
thermoplastic polymer, the bone interfacing surface may be modified
to include an IPN/semi-IPN to strengthen the implant and facilitate
adhesion of the device to a bone cement. In such embodiments, the
monomer P' solution is placed in contact with the thermoset or
thermoplastic polymers in the bone interfacing surface of the
device. The monomer P' solution is allowed to diffuse into the
implant to the extent sufficient to impart adhesiveness and higher
mechanical strength in the target location of the implant.
[0316] Affecting the amount or degree of diffusion into the implant
can be accomplished by controlling the conditions of the diffusion.
For example, conditions that can affect the degree of IPN
penetration include modifying exposure time to the monomer P'
solution, grade of the solid form, concentration of the monomer P'
solution, region(s) of the solid form exposed, etc. By modifying
any number or combination of these conditions (or others) the
regions and degrees of adhesiveness, stiffness, shear strength,
etc. can be adjusted to a suitable amount.
[0317] In additional embodiments, a solvent can be used to deliver
monomers that otherwise would not mix easily (or solubilize) with
the polymer or to one (or more phases) of the polymer. Solvents
that can be used include, but are not limited to, di- or
trichloromethane and dimethyl sulfoxide (DMSO). Depending on the
solubilities in the phases of the polymer, solvents with varying
degrees of swelling the polymer can be determined. Solubilities of
the solvents and component material to be swollen can be obtained
from polymer textbooks such as The Polymer Handbook or measured
experimentally.
[0318] In another aspect of the invention, a concentration gradient
can form within the starting homopolymer or thermoset/thermoplastic
polymer. As shown in FIG. 2, a gradient can form in a material 20
along a thickness direction, with the IPN formed on one side 22 and
extending in a diminishing concentration to another side 24, e.g.,
substantially only homopolymer. In FIG. 3, the IPN concentration
gradient is radial within material 30, with the outer surface 32
being the highest concentration of IPN and the center or core 34
having the lowest concentration of IPN. A reverse gradient can also
be made in the case of a cylinder or a sphere, with the IPN
disposed in the core of the shape and the hydrophobic polymer being
disposed in the outer aspect of the shape.
[0319] In some embodiments, a concentration gradient can be created
by employing an IPN in a homopolymer where the concentration of the
IPN changes from one region of the starting material to another.
For example, a monomer solution that is allowed to diffuse into
only one side of a polyurethane solid form will form an IPN through
a thickness on that side of the solid form. The resulting material
can contain a side with pure polyurethane and a side with IPN.
Within the IPN side, the concentration of the penetrating polymer
may not be uniform and, in some instances, will show a higher
concentration of penetrating polymer at the site of direct exposure
(surface that was in direct contact with the monomer solution) and
diminishing concentration of the penetrating polymer through a
thickness of the solid form from the site of direct exposure. A
transition area may exist between the IPN and the pure polyurethane
regions where the concentration of the penetrating polymer
diminishes until effectively the IPN region merges with a non-IPN
region of pure polyurethane.
[0320] FIG. 60 illustrates how the concentration gradient of the
hydrophobic polymer and the non-ionic polymer can vary across the
thickness (between the two surfaces) of a gradient IPN. The
composition gradient yields a property gradient in which the IPN is
adhesive and stiff on one side, and less adhesive (or not adhesive)
and less stiff on the other.
[0321] In some variations, a concentration gradient can form by
adjusting the exposure time or area of the thermoset/thermoplastic
polymer in a monomer solution. Similarly, a concentration gradient
can also result by limiting the exposure time of the solid form to
the monomer solution. Depending on these and other factors, a
gradient of material composition across a section (e.g. thickness)
of the polyurethane solid form can be achieved.
[0322] By way of example, a concentration gradient can be created
in a solid form of polyurethane by exposing one side of the solid
form to a MMA solution. The MMA monomers penetrate the solid form
through the contact side but can be limited in the degree of
diffusion by factors such as the area available for penetration,
exposure time, and the structure of the solid form (e.g. phases
present in the thermoset/thermoplastic polymer). Once the MMA
monomers are allowed to diffuse through one side of the solid form,
the monomers are polymerized to form a PMMA IPN/semi-IPN within the
solid form. In this example, the resulting material can exhibit a
concentration or composition gradient with the IPN/semi-IPN on one
side, the thermoset/thermoplastic polymer on another side, and a
transition region with decreasing PMMA content from one side to the
other. In some embodiments, the concentration gradient allows
regions of the starting structure to exhibit properties such as
greater stiffness, adhesiveness, or strength while at the same time
preserving sections having the original material.
[0323] The use of concentration gradients within
thermoset/thermoplastic polymer materials is especially
advantageous in the creation of osteochondral grafts for
orthopaedic joint replacement materials. For instance, in the case
of a joint arthoplasty, the bone interfacing side of a polyurethane
implant is exposed to a MMA monomer such that it forms a
PMMA-polyurethane IPN through a thickness of the implant. While one
side of the implant remains pure thermoplastic, the bone
interfacing surface exhibits greater adhesiveness while the IPN
also provides increased mechanical strength through the thickness
of the implant where the IPN exists. A PMMA bone cement can be
applied to the IPN (bone interfacing) surface to facilitate bonding
of the implant to a bone surface.
[0324] In further embodiments, the starting material for the
concentration gradient is a lubricious hydrophobic
thermoset/thermoplastic material. Such materials may be one of
those previously discussed such as a thermoset or thermoplastic
polymer with a lubricious IPN/semi-IPN. For example, an orthopaedic
device 900 that is designed to replace femoral head cartilage is
shown in FIGS. 58A-B. The orthopaedic device 900 comprises a
lubricious polyurethane based material. To impart adhesiveness to
the bone contacting surface, internal bone contacting area 903 and
surface 904 is infused with a MMA monomer according to the method
described above. The MMA monomer is then polymerized, forming an
IPN/semi-IPN layer in the bone contacting surface 904 and through a
thickness in the bone contacting area 903. The resulting implant
has a bone contacting area 903 and surface 904 with adhesive
properties, a stiffness gradient through the thickness of the
implant, and an external unmodified area 906 with an unmodified
surface 902. The dotted line 908 shows a general illustration of a
transition area between the IPN and the unmodified starting
material. Although the dotted line 908 indicates the general area
at which the gradient fades out and transitions to a pure
polyurethane (or non-IPN) portion, this transition area can be
anywhere along the thickness of the implant or may be absent
altogether in other embodiments. In other embodiments, no discrete
boundary exists between the PMMA-polyurethane IPN and the
unmodified lubricious polyurethane portions of the device.
[0325] The polyurethane of the example above may be formed by any
process and may contain any additional materials, including but not
limited to those described in U.S. patent application Ser. No.
12/148,534 filed Apr. 17, 2008 and entitled "Hydrogel Arthroplasty
Device", U.S. patent application Ser. No. 12/499,041, filed Jul. 7,
2009, and entitled "Hydrophilic Interpenetrating Polymer Networks
Derived from Hydrophobic Polymers", U.S. patent application Ser.
No. 12/536,233 filed Aug. 5, 2009 and entitled
"Polyurethane-Grafted Hydrogels".
[0326] As described above, the forming or shaping of the IPN and
semi-IPN articles according to embodiments of this invention can be
done prior to or after creating the IPN/semi-IPN in the material.
For example, a solid form of polyurethane can be pre-formed into a
joint implant having a bone interfacing surface and a joint
interfacing surface. The implant is then exposed to a monomer
solution, which is polymerized to an IPN/semi-IPN in the
implant.
[0327] Another aspect of the invention takes advantage of the high
mechanical strength of thermoset or thermoplastic polymers and the
ability to modify these materials to impart more than one desired
property. For example, a thermoset or thermoplastic polymer can be
made lubricious, conductive, and adhesive through the use of
combinations of monomers and IPNs.
[0328] More than one property can be imparted to a hydrophobic
thermoset/thermoplastic polymer by introducing a first monomer
solution into the thermoset/thermoplastic polymer and polymerizing
to form a first IPN/semi-IPN in the thermoplastic polymer. The
process can be further repeated to introduce additional
IPNs/semi-IPNs to the starting polymer.
[0329] This process is particularly useful where different sections
of the starting material require different properties or sets of
properties from other sections. For example, a polyurethane femoral
head cap implant has a bone interfacing surface that will engage
and affix to a femur surface and a joint interfacing surface that
will engage the hip socket. To securely affix the implant to the
bone, implant's bone interfacing surface can be infused with a
monomer (e.g. MMA) solution capable of imparting adhesiveness,
stiffness, or strength. With a MMA solution, the MMA monomers
penetrate the bone interfacing surface of the implant and
polymerize to form a PMMA-polyurethane IPN/semi-IPN in the bone
interfacing surface. On the joint interfacing surface, a
hydrophilic polymer can impart a lubricious surface that mimics
natural cartilage. To do so, the joint interfacing surface is
infused with an ionic monomer solution that polymerizes to form a
hydrophilic IPN/semi-IPN in the joint surface.
[0330] In some embodiments, the multiple IPNs/semi-IPNs share the
same starting thermoset/thermoplastic polymer with different
penetrating polymers. This can be understood as a material
containing an IPN/semi-IPN with a penetrating polymer P and a
thermoset or thermoplastic polymer T and another IPN/semi-IPN with
the same thermoset/thermoplastic polymer T and a penetrating
polymer S. Multiple IPNs/semi-IPNs can exist in the same,
overlapping, or distinct regions of the starting material. In the
implant example above, the adhesive IPN on the bone interfacing
surface and the lubricious IPN on the joint interfacing are
disposed on different sides of the implant where the two IPNs do
not overlap. However, multiple IPNs may coexist or overlap in
sections of the material. Similarly, in some embodiments, multiple
IPNs may overlap in certain portions of the material but not in
others. Additionally, starting material or non-IPN region may be
disposed adjacent to an IPN section such that the starting material
region is next to one or more IPN sections. For example, a starting
material region may be "sandwiched" between two IPN regions.
[0331] Moreover, the multiple IPNs/semi-IPNs do not necessarily
provide different properties to the material. Some materials
contemplated include more than one lubricious portion while other
materials may have multiple adhesive sections. In embodiments where
more than one bonding agent is used on a material, it is understood
that the same IPN may not have the same degree of affinity to the
different bonding agents (e.g. a PMMA-IPN may not adhere as well to
bone cement with a high polystyrene content). In such cases,
different penetrating polymers may be used to form different
adhesive IPNs where each IPN is configured to optimize bonding with
a target substance or material.
[0332] Alternatively, the multiple IPNs/semi-IPNs may employ the
same penetrating polymer. For example, a polyurethane solid form
may contain a PMMA-polyurethane-IPN on two different surfaces. In
some instances, one IPN may be formed first and a second IPN with
the same penetrating polymer formed at a later time.
[0333] Furthermore, as can be appreciated in the art, any
combination of hydrophobic, non-ionic, hydrophilic, and ionic
polymers can be used with a thermoset/thermoplastic starting
polymer to create one or more IPNs/semi-IPNs in the starting
polymer. For example, a material may contain two hydrophobic or two
hydrophilic IPNs or combinations, variations, or permutations
thereof.
[0334] As discussed, in some embodiments, the process of preparing
multiple IPNs/semi-IPNs in a thermoset or thermoplastic polymer
solid form includes the steps of placing at least one region of the
solid form in contact with a monomer solution, diffusing the
monomer solution into the thermoset/thermoplastic polymer,
polymerizing the monomer into a penetrating polymer, and repeating
these steps with additional monomer solutions. In other
embodiments, the thermoset or thermoplastic polymer solid form is
exposed and swollen with each of the monomer solutions before
polymerization of the monomers into their respective penetrating
polymers. Depending on the desired product, the process can be
modified to adjust the placement of the IPNs/semi-IPNs. For
example, each of the IPNs/semi-IPNs can overlap or exist in
separate regions of the hydrophobic thermoset or thermoplastic
polymers.
[0335] In additional embodiments, more than one concentration
gradient can form in a thermoset/thermoplastic polymer with
multiple IPNs/semi-IPNs. In some instances, a material having two
IPNs (or more) may have two or more concentration gradients where
each gradient provides regions of varying degrees of penetrating
polymer concentration and varying degrees of imparted properties.
As with the gradients discussed previously, the concentration
gradient can be created by adjusting conditions such as the
thermoset/thermoplastic polymer's exposure area and time to a
monomer solution. By adjusting conditions for one or more of the
monomer solutions employed, multiple concentration gradients can
exist in the starting material.
[0336] For example, FIGS. 59A-C show an othropaedic device 910 that
is meant to replace femoral head cartilage. The device 910 is made
from a polyurethane starting material that is infused with two
monomer solutions to form two concentration gradients on separate
regions of the device 910. The orthopaedic device 910 has an
external contact surface 912 designed to engage the hip joint and
an internal surface 914 designed to engage the surface of the
femur. A hydrophilic monomer can be diffused into the polyurethane
starting material on the external contact surface 912 and
polymerized to form a lubricious IPN. Additionally, a non-ionic
monomer such as MMA can be diffused into the polyurethane starting
material on the internal contact surface 914 and polymerized to
form an adhesive, stiffness, strength gradient (and an adhesive
surface).
[0337] In some embodiments, this process forms two IPNs with two
concentration gradients, one on the lubricious side with surface
912 and one on the anchoring side with surface 914. The
concentration gradient on the lubricious side may exhibit
diminishing concentration of the penetrating polymer through a
thickness of the implant, whereby the properties of the IPN may
also decrease through a thickness of the implant in relation to the
concentration of the penetrating polymer in the IPN. For example,
an IPN area of higher concentration of the penetrating polymer may
have a higher degree of lubriciousness than an area of lower
concentration. Similarly, on the anchoring side with surface 914,
the concentration of the penetrating non-ionic polymer may also
diminish from one region to another through the IPN and afford a
relative reduction in adhesiveness through the same area.
[0338] Because there are numerous ways of creating and placing
multiple IPNs (and concentration gradients) on a starting material,
behavior of a concentration gradient is not limited to diminishing
concentration of a penetrating polymer through a thickness of a
starting material. Gradients can be formed across a surface rather
than a thickness of a material. Moreover, multiple IPNs may overlap
partially or fully at regions in the starting material, or
alternatively, multiple IPNs may be placed in distinct and separate
regions. For example, FIGS. 59B and 59C show a region 916 between
the two IPNs concentration gradients that remains as unmodified
starting polyurethane material. Dotted line 918 shows generally a
transition area between the concentration gradient on the
lubricious side with surface 912 and the area of pure polyurethane
material 916. Similarly, dotted line 920 shows generally a
transition area between the concentration gradient on the anchoring
side with surface 914 and a region of pure starting material 916.
Although shown as dotted lines in 918 and 920, the transition areas
contemplated do not require a discrete boundary between an IPN and
the unmodified polyurethane material. In some embodiments, more
than one gradient can meet in a portion of the starting material
without a transition area from one gradient to pure starting
material. In some embodiments, the transition area between
gradients or gradients and starting material can be anywhere along
a dimension of the material (e.g. implant) or may be absent
altogether. Alternatively, in further embodiments, IPNs and
gradients can be prepared such that the transition areas, points,
regions between IPNs, gradients, or starting materials distinctly
separate differing areas by way of boundaries or layers.
[0339] In the above example, it is understood that the multiple
IPNs/semi-IPNs share the same starting thermoset/thermoplastic
polymer with different penetrating polymers. This can be understood
as an implant containing an IPN/semi-IPN with a penetrating polymer
P and a thermoset or thermoplastic polymer T and another
IPN/semi-IPN with the same thermoset or thermoplastic polymer T and
a penetrating polymer S. In additional embodiments, the hydrophobic
thermoset/thermoplastic material can include more than a double
gradient, e.g. triple or more gradients imparted by multiple
IPNs/semi-IPNs.
[0340] FIGS. 61A-61B illustrate one embodiment of a double gradient
with a lubricious and adhesive gradient disposed on two different
sides with a region of pure thermoset polymer 1005 between the
gradients. The thermoset polymer material 1000 shown in FIGS. 61A
and 61B has two gradients formed by two IPNs on two regions of the
material 1000. The lubricious gradient is disposed in region 1003
and is formed from an IPN/semi-IPN made from a hydrophilic polymer
S network within the thermoset polymer material T. The lubricious
IPN area 1003 includes a surface section 1001 that provides a
lubricious surface to engage with, for example, a joint region. On
the other side of the material, is an adhesive gradient 1004 formed
from an IPN/semi-IPN with a non-ionic polymer P network within the
thermoset polymer material T. The adhesive IPN area 1004 includes a
surface section 1002 that provides an adhesive surface to engage
with bone through use of a cement 1006. As shown in FIG. 61A, the
gradient regions 1003, 1004 and pure thermoset region 1005 are not
separated in this embodiment by distinct boundaries. Rather, the
regions gradually merge and transition from one to the other
through a thickness of the material. For example, the concentration
of the non-ionic polymer P network in region 1004 is shown as
slanted lines that darken and widen from the pure thermoset region
1005 to the adhesive surface 1002. This shows that in some
embodiments, the concentration of the non-ionic polymer P and the
relative concentration of the adhesive gradient gradually increases
from one region of the thermoset material to another without
forming distinct boundaries between the sections. Similarly, on the
lubricious side, the slanted lines showing the hydrophilic polymer
S are wider and darker near the surface 1001 and gradually lighten
as the slanted lines move toward the pure thermoset region 1005.
This also shows that in some embodiments, the concentration of
hydrophilic polymer S is greater at the surface 1001 and gradually
diminishes through a thickness of the material toward region 1005.
FIG. 61B further illustrates that in some embodiments, once the
cement or anchoring compound 1006 is applied to the adhesive
surface, the cement and the adhesive gradient merge to form a
continuous region 1007 and a cemented side 1008 without distinct
boundaries between the anchoring compound and the adhesive gradient
1004. In further embodiments, where the non-ionic polymer P in the
cement 1006 and the adhesive IPN are the same (as indicated by the
presence of the slanted lines in cement 1006 and region 1004), the
non-ionic polymer P in the IPN and in the cement will merge and
fuse to form a continuous composition.
[0341] FIGS. 62A-E show osteochondral grafts formed from a
non-ionic IPN or semi-IPN of this invention that may be used singly
or in any combination needed to replace or augment cartilage within
a knee joint. FIG. 62A shows a osteochondral graft 1110 adapted to
engage the femoral condyles (or alternatively, just one condyle).
FIG. 62B shows osteochondral grafts 1111 and 1112 adapted to engage
one or both sides of the tibial plateau 1113. FIG. 62C shows an
osteochondral graft 1118 adapted to engage the patella 1114 and to
articulate with an osteochondral graft 1119 adapted to engage the
patellofemoral groove 1115. FIG. 62D show osteochondral grafts 1116
and 1117 adapted to engage the lateral and medial menisci. FIG. 62E
shows how some of these prostheses may be assembled in place within
the knee joint. Any of the IPNs/semi-IPNs as described and
contemplated herein can be used with grafts such as those in FIGS.
62A-E to provide advantageous properties such as adhesiveness,
stiffness, lubricity, conductivity, etc.
[0342] Moreover, in some embodiments, gradients such as those
described in FIGS. 61A-B are employed where applicable to provide a
lubricious and an adhesive gradient in the graft. For example,
osteochondral graft 1110 can contain an adhesive surface and
adhesive gradient on the portion of the graft adapted to engage the
bone surface of the femoral condyles. Osteochondral graft 1110 may
also include a lubricious surface and lubricious gradient to engage
the tibial plateau 1113. As shown in FIG. 62B, the tibial plateau
1113 may also include osteochondral grafts 1111 and 1112 that can
contain double gradients as described including an adhesive
gradient with an adhesive surface on a tibia bone interfacing
surface and a lubricious gradient and lubricious surface on a joint
interfacing surface. Similarly, the gradients as described can be
used in any, some, or all of the described grafts in FIGS.
62A-E.
[0343] In a further example, FIG. 63 shows two sides of a generic
articular joint with both sides of the joint replaced with
components or devices of the current disclosure. Concave bony
prominence 1010 has a bone interface 1012 which accepts a concave
articular component 1014. Convex bony prominence 1016 has a bone
interface 1017 which accepts a convex articular component 1018.
Concave component articular component 1014 mates with convex
articular component 1018 at articular interface 1020. Any of the
components may include a cross section such as the cross section at
1022 with single or multiple IPNs/semi-IPNs as described (such as
those in FIGS. 61A and 61B). For example, cross section 1022 may
contain a lubricious gradient and a lubricious surface on the joint
interface portion facing the joint interface region 1024 where
articular components 1014 and 1018 meet at 1020. An adhesive
surface and adhesive gradient may be disposed on the bone
interfacing portion facing the bone interface 1012.
[0344] FIG. 64 illustrates another embodiment with the placement of
a cap-on-cup with a convex articular component cap 1024 over a
femoral head 1028 and a concave articular component cup 1026 facing
an acetabulum 1030 without the synthetic joint capsule and
synthetic labral components in place. These components can be made
with the thermoset/thermoplastic polymer materials with the
IPN(s)/semi-IPN(s) and gradient(s) described. One or more of these
components can include gradients such as those shown in FIGS. 61A
and 61B.
[0345] The components and devices described can be formed into any
number of designs for use such as grafts, patches, plugs, and total
surface replacement. For example, FIGS. 65-68 provide examples of
shapes employed with various embodiments. FIG. 65 shows an
osteochrondral graft formed to fit over a surface of a femur. The
device is formed as a patch 1032 to cover the femoral condyles of
femur 1034. The patch 1032 may contain one or more IPNs/semi-IPNs
that provide a gradient (or gradients) through a region(s) of the
patch 1032. For example, the patch 1032 may contain an adhesive
surface on the bone interfacing surface to facilitate affixing the
patch 1032 to the femoral condyles via an anchoring agent.
[0346] In further embodiments, the graft, patch, plug, etc. may be
implants or devices designed to partially cover or replace
cartilage surface. FIGS. 66A and 66B illustrate examples of various
forms of osteochrondral grafts that provide partial replacement.
FIG. 66A illustrates a smaller graft 1038 that may be used in lieu
of larger graft 1036 to resurface the patellofemeroal groove.
Similarly, FIG. 66A shows a plug 1042 and a smaller patch 1040 that
can be used to replace a region of the femoral condyles as an
alternative to a larger patch 1044.
[0347] Additionally, FIG. 67 illustrates a full distal femoral
cartilage replacement component according to embodiments of this
invention where the graft 1045 is placed over the distal surface
1046 of the femur.
[0348] FIG. 68 provides another example of an osteochrondral plug
with a lubricious gradient and a stiffness gradient that are
disposed on different sides with overlapping regions.
[0349] In some embodiments, an osteochondral graft such as a plug
with one or more IPNs/semi-IPNs may also include a porous bone
interfacing material. The porous bone interfacing layer can be
added to a bone interfacing portion of a device to facilitate bone
ingrowth and integration. In some embodiments, a lubricious,
cartilage-like synthetic region and surface may be disposed on one
side of the graft and an adhesive bone interfacing region and
surface may be anchored to another side. The adhesive bone
interfacing region may further include a porous bone or a
synthetic, porous bone-like structure. In one embodiment, the
lubricious region consists of an interpenetrating polymer network
that is composed of two polymers. The first polymer may be a
hydrophobic thermoplastic with high mechanical strength, including
but not limited to polyether urethane, polycarbonate urethane,
silicone polyether urethane, and silicone polycarbonate urethanes,
or these materials with incorporated urea linkages, or these
materials with incorporated urea linkages (e.g. polyurethane urea).
The second polymer may be a hydrophilic polymer derived from
ionizable, vinyl monomers, including but not limited to acrylic
acid and/or sulfopropyl methacrylate.
[0350] The adhesive region may consist of another interpenetrating
polymer network that is composed of the same hydrophobic
thermoplastic polymer of the lubricious region and a non-ionic
polymer such as PMMA. A porous bone interface material, such as the
one shown in FIG. 69 may be applied to the surface of the adhesive
region to help facilitate attachment of the graft with the target
bone location. In further embodiments, the porous bone interface
material may itself contain IPNs/semi-IPNs or gradients.
[0351] In further examples, the devices and components of the
embodiments described may include a porous bone-interfacing
material or layer such as the ones shown in FIGS. 72-75. In FIG.
72, a synthetic osteochondral plug consists of a lubricious,
cartilage-like bearing surface 1048 that transitions to a
bone-interface region 1050 with a porous surface 1052 to facilitate
bone ingrowth. FIG. 73 provides an example of an injection molded
hemispherical shell with a porous backing. FIG. 74A provides an
example of an injection-molded design with pyramidal surface
feature indentations. FIG. 74B provides an enlarged view of the
pyramidal surface features on 74A. As discussed, these porous
bone-interfacing materials can be used with any of the devices,
components, and materials described herein (including those with
one or more IPNs/semi-IPNs and gradients).
[0352] FIG. 75A-C provide a further osteochrondral plug embodiment
of the described invention. FIG. 75A shows the cross section of
plug 1054. The plug 1054 has a bearing surface 1056 and a bone
interfacing surface 1058. The plug is implanted through a layer of
cartilage 1060, calcified cartilage 1062, and subchondral bone
1064. In some embodiments, the curvature of the bearing surface
1054 will match that of the cartilage 1060 at the implantation site
to minimize contact stresses in the apposing cartilage. The outer
edge has a greater curvature to avoid "catching" during
sliding-contact and to facilitate cartilage growth toward the
device. The plug 1054 may also contain one or more IPNs/semi-IPNs
and gradients.
[0353] FIG. 75B provides the osteochrondral plug of FIG. 75A with a
bone-interface surface with the addition of larger grooves 1066
(depth=750 .mu.m, width=1500 .mu.m) to enhance biologic fixation.
FIG. 75C shows the plug of FIG. 75A further including a porous
bone-interfacing surface 1070 made from sintered beads 1068. In
some embodiments the pore size is approximately 100-400 .mu.m.
[0354] Furthermore, although the starting polymers have been
described as hydrophobic thermoset or thermoplastic polymers, other
suitable starting polymers known in the art such as polyethylene
glycol or polyvinyl alcohol may be used as a starting material.
[0355] Another aspect of the present invention relates to a group
of new polyurethane structures (polyurethane-polyacrylic acids;
PU-PAA) and their IPNs which provide superior hydrolytical
resistance, oxidative stability and creep resistance through
covalently bonded crosslinks. In further embodiments, medical
devices such as prostheses for a body, including joint prostheses
are made from these materials.
[0356] In some embodiments, the new group of polyurethane
structures may form polyurethane precursor material with structural
integrity similar to Elasthane.TM. grade polyurethanes, such as
resistance to hydrolysis and/or oxidation and/or creep; allow for
cross linking with a subsequently added second network that is
formed by polymerizing acrylic acid that has previously swollen the
polyurethane; and/or allow for subsequent covalent bond formation
between antioxidant(s) and polyurethane soft segment (s) after the
acrylic acid polymerization.
[0357] Although a commercially available polyurethane product,
Elasthane, Bionate, Pursil, or Sylgard, was used in some examples
as a suitable polyurethane hydrophobic thermoset/thermoplastic
polymer, it is understood in the art that any suitable polyurethane
containing material may be used and there is no limitation as to
the particular commercial products/tradenames described herein.
[0358] In some embodiments, example raw materials for the new group
of polyurethane structures contemplated are hydroxy-terminated
polybutadiene (HTPB) (FIG. 76) and bis-methylenediphenyl
diisocyanate (MDI) (FIG. 77). Alternatively, any other
isocyanate(s) can be used, such as HDI, TDI, etc. In addition, any
other diol(s) may be used with and without the dangling vinyl
group. The diol may have a double bond in the chain.
[0359] Moreover, alternatively, mixtures of HTPB and PTMO or PEG
can be used with a concentration that varies from 1-99%. PTMO:
polytetramethyleneoxide, PEG: polyethylene glycol.
[0360] In some variations, the polymers are prepared according to
the following reactions:
MDI+HTPB------->OCN-MDI-HTPB-MDI-NCO to form a prepolymer in
bulk.
[0361] Any solvent or mixture of solvents may be used to form the
prepolymer (e.g. dimethylacetamide (DMAC), dimethylformamide (DMF),
dimethylsulfoxide (DMSO), or toluene). The prepolymer is then
chain-extended with diols such as butanediol (BD). Any diol or a
mixture of diols can be used. The relative ratio of HTPB and PTMO
or other soft segment (diol) and/or the molecular weight of the
HTPB can be adjusted in order to provide final PUs with desired
mechanical properties.
[0362] In some embodiments, the resultant PU is soaked with a
mixture of aqueous acrylic acid, (photo) initiator and cross-linker
and polymerized using any method (e.g. ultraviolet (UV) light,
thermal energy, atomic transfer radical polymerization (ATRP),
reversible addition-fragmentation chain transfer (RAFT), emulsion
polymerization) to form a hybrid of semi-IPN and IPN. PAA (FIG. 79)
is spontaneously copolymerized with the dangling vinyl group on the
(HTPB) chain to form the material shown in FIG. 80.
[0363] Any initiator and any cross-linker soluble in the acrylic
acid solution may be used. The initiator maybe any, e.g. a photo or
thermal initiator (2-hydroxy-2-methylpropiophenone, AIBN,
4,4'-azobis(4-cyanovaleric acid), V-501 by Wako, or V-44(Wako). The
cross-linker may be any e.g. bis-acylamide, bis-acrylate,
bis-methyacrylate, PEG-diacrylate, or divinylether. The IPN is
further modified with an antioxidant such as a hindered-phenol
acrylate as shown in FIG. 78. Any antioxidant that has a double
bond may be used.
[0364] The antioxidant can be covalently bonded to the PU-PAA
described in this disclosure through a [2+2]cycloaddition with the
--C.dbd.C-- bonds on the HTPB. A covalently bonded antioxidant will
not leach out throughout life time of a medical device made out of
the PU-PAA IPN using UV irradiation. The final structure of the end
material is shown in FIG. 81.
[0365] In some embodiments, the resultant material has some or all
of the following superior properties: excellent hydrolytical
stability; excellent oxidative stability; superior hard segment
integrity, reducing the creep and increasing device dimensional
stability; extremely low cell adhesion; extremely low protein
absorption; better biocompatibility; and no PAA leaching during the
lifetime of the device.
[0366] As for additional details pertinent to the present
invention, materials and manufacturing techniques may be employed
as within the level of those with skill in the relevant art. The
same may hold true with respect to method-based aspects of the
invention in terms of additional acts commonly or logically
employed. Also, it is contemplated that any optional feature of the
inventive variations described may be set forth and claimed
independently, or in combination with any one or more of the
features described herein. Likewise, reference to a singular item,
includes the possibility that there are plural of the same items
present. More specifically, as used herein and in the appended
claims, the singular forms "a," "and," "said," and "the" include
plural referents unless the context clearly dictates otherwise. It
is further noted that the claims may be drafted to exclude any
optional element. As such, this statement is intended to serve as
antecedent basis for use of such exclusive terminology as "solely,"
"only" and the like in connection with the recitation of claim
elements, or use of a "negative" limitation. Unless defined
otherwise herein, all technical and scientific terms used herein
have the same meaning as commonly understood by one of ordinary
skill in the art to which this invention belongs. The breadth of
the present invention is not to be limited by the subject
specification, but rather only by the plain meaning of the claim
terms employed.
* * * * *