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WO2011072212A2 - Procédé de fabrication d'implants antimicrobiens en polyétheréthercétone - Google Patents

Procédé de fabrication d'implants antimicrobiens en polyétheréthercétone Download PDF

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Publication number
WO2011072212A2
WO2011072212A2 PCT/US2010/059868 US2010059868W WO2011072212A2 WO 2011072212 A2 WO2011072212 A2 WO 2011072212A2 US 2010059868 W US2010059868 W US 2010059868W WO 2011072212 A2 WO2011072212 A2 WO 2011072212A2
Authority
WO
WIPO (PCT)
Prior art keywords
peek
zeolite
antimicrobial
silver
polyetheretherketone
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2010/059868
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English (en)
Other versions
WO2011072212A3 (fr
Inventor
Joseph J. Crudden
Jami Hafiz
James E. Deaton
John R. Pepper
Derrick Johns
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Difusion Technologies Inc
Original Assignee
Difusion Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Difusion Technologies Inc filed Critical Difusion Technologies Inc
Priority to RU2012129171/15A priority Critical patent/RU2526168C2/ru
Priority to CN201080063584.7A priority patent/CN102834122B/zh
Priority to EP10836743.4A priority patent/EP2512538B1/fr
Priority to US13/512,702 priority patent/US8821912B2/en
Priority to BR112012016027-3A priority patent/BR112012016027B1/pt
Publication of WO2011072212A2 publication Critical patent/WO2011072212A2/fr
Publication of WO2011072212A3 publication Critical patent/WO2011072212A3/fr
Anticipated expiration legal-status Critical
Priority to US13/653,896 priority patent/US8840914B2/en
Priority to US14/471,329 priority patent/US9132576B2/en
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0013—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor using fillers dispersed in the moulding material, e.g. metal particles
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/14—Macromolecular materials
    • A61L27/18—Macromolecular materials obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/50—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L27/54—Biologically active materials, e.g. therapeutic substances
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P31/00—Antiinfectives, i.e. antibiotics, antiseptics, chemotherapeutics
    • A61P31/04—Antibacterial agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B13/00—Conditioning or physical treatment of the material to be shaped
    • B29B13/02—Conditioning or physical treatment of the material to be shaped by heating
    • B29B13/022—Melting the material to be shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B13/00—Conditioning or physical treatment of the material to be shaped
    • B29B13/06—Conditioning or physical treatment of the material to be shaped by drying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/003—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material
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    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/26—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length in several steps
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0005—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor using fibre reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2300/00—Biologically active materials used in bandages, wound dressings, absorbent pads or medical devices
    • A61L2300/10—Biologically active materials used in bandages, wound dressings, absorbent pads or medical devices containing or releasing inorganic materials
    • A61L2300/102—Metals or metal compounds, e.g. salts such as bicarbonates, carbonates, oxides, zeolites, silicates
    • A61L2300/104—Silver, e.g. silver sulfadiazine
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2300/00—Biologically active materials used in bandages, wound dressings, absorbent pads or medical devices
    • A61L2300/40—Biologically active materials used in bandages, wound dressings, absorbent pads or medical devices characterised by a specific therapeutic activity or mode of action
    • A61L2300/404—Biocides, antimicrobial agents, antiseptic agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2071/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
    • B29K2105/0011—Biocides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
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    • B29K2105/16—Fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2307/00—Use of elements other than metals as reinforcement
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2505/00—Use of metals, their alloys or their compounds, as filler
    • B29K2505/08—Transition metals
    • B29K2505/14—Noble metals, e.g. silver, gold or platinum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2709/00—Use of inorganic materials not provided for in groups B29K2703/00 - B29K2707/00, for preformed parts, e.g. for inserts
    • B29K2709/02—Ceramics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
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Definitions

  • Implantable medical devices are implanted into the body for various reasons, including orthopedics (e.g., hip replacement, spinal procedures, knee replacement, bone fracture repair, etc.) .
  • orthopedics e.g., hip replacement, spinal procedures, knee replacement, bone fracture repair, etc.
  • materials of fabrication are limited, and conventionally include metal, plastic and composites .
  • MRSA Methicillin- resistant Staphylococcus aureus
  • Biofilms can facilitate the proliferation and transmission of microorganisms by providing a stable protective environment. These biofilms, when well developed, can disseminate bacterial planktonic showers which can result in broad systemic infection.
  • Bioengineered materials act as excellent hosts for the formation of bacterial biofilms. Occasionally, the implant itself carries the infecting organism, and the implants develop very tenacious biofilms seeded by infecting organisms. When this occurs, usually the implant must be removed, the patient must be treated with a prolonged course of one or more antibiotics in an effort to cure the infection, and a new implant is then re-implanted. This obviously subjects the patient to additional trauma and pain, and is extremely expensive.
  • Ceramics such as zeolite function as a cation cage, being able to be loaded with silver and other cations having antimicrobial properties.
  • Metal zeolites can be used as an antimicrobial agent, such as by being mixed with the resins used as thermoplastic materials to make the implantable devices, or as coatings to be applied to the devices; see, for example, U.S. Patent No. 6,582,715, the disclosure of which is hereby incorporated by reference.
  • the antimicrobial metal zeolites can be prepared by replacing all or part of the ion-exchangeable ions in zeolite with ammonium ions and antimicrobial metal ions. Preferably, not all of the ion-exchangeable ions are replaced.
  • thermoplastic resin that has been found to be useful in an implant is polyetheretherketone (PEEK) .
  • PEEK polyetheretherketone
  • This thermoplastic polymer has an aromatic backbone, interconnected by ketone and ether functionality.
  • PEEK is suitable for implants because its modulus closely matches that of bone, and is resistant to chemical and radiation damage.
  • Grades of PEEK approved for implantation are very pure and inert and need to pass stringent cytotoxicity testing before being allowed to be implanted into mammals.
  • the ISO 10993 set entails a series of standards for evaluating the biocompatibility of a medical device prior to a clinical study. These documents were preceded by the Tripartite agreement and are a part of the harmonization of the safe use evaluation of medical devices. Those standards include :
  • metal zeolite can release moisture if it is not extremely dry. This moisture can cause the formation of voids in the polymer melt and can contribute to the decomposition of the PEEK polymer and to oxidation of metals, such as silver, copper and/or zinc, incorporated into the zeolite antimicrobial. Although the presence of voids may not be critical for certain non-load bearing applications, the absence of voids is critical for load-bearing applications such as spinal repair.
  • metal zeolites If the process of incorporating metal zeolites is carried out in air, severe oxidation can occur as the temperature is raised, and moisture and oxygen come into contact with the metal ions. Silver will rapidly darken to a dark brown or black color. Also, the incorporation of significant quantities of metal zeolites into the PEEK polymer can affect the viscosity and rheology of the composition .
  • the present disclosure is based on the finding that it is possible, under conditions of high temperature and high shear, to incorporate antimicrobial zeolite, such as silver zeolite, into PEEK, such as by mixing doped metal zeolites into molten PEEK (melting point between 300 and 400°C, depending on purity) , followed by molding and processing of the composite blend.
  • antimicrobial zeolite such as silver zeolite
  • PEEK such as by mixing doped metal zeolites into molten PEEK (melting point between 300 and 400°C, depending on purity)
  • the result is the provision of medical devices such as implants with effective antimicrobial activity in order to reduce the growth of bacteria and risk of infection.
  • the shortcomings of the prior art have been overcome by the present disclosure, which relates to methods of fabricating implantable medical devices, preferably with PEEK, having antimicrobial properties.
  • the antimicrobial effect is produced by incorporating ceramic particles containing antimicrobial metal cations into molten PEEK resin, which is subsequently allowed to cool and set in its final shape achieved by injection molding, cutting and machining or other techniques.
  • the rate of release of metallic ions is governed by the extent of loading of the plastic with ceramic particles containing metal ions and the loading of metal in the ceramic material.
  • the electrolyte concentration in blood and body fluids is relatively constant and will cause ion exchange with ions such as silver, copper and zinc, and others from the surface of the implant, which deactivate or kill gram positive and gram negative organisms, including E. coli and Staphylococcus aureus.
  • Effective antimicrobial control of a six-log reduction of microorganisms is achieved, for example, at metal zeolite concentrations of 4% or greater.
  • the devices are implantable into animals, particularly humans. Spinal implants are particularly contemplated .
  • Fig. 1 is a perspective view of a cervical spacer in accordance with certain embodiments.
  • Embodiments disclosed herein relate to the processing of ceramics, preferably zeolites, as a cation cage in combination with medical implants to deliver and dose one or more antimicrobial cations.
  • ceramics preferably zeolites
  • other suitable ceramic antimicrobial materials include hydroxy apatite, zirconium phosphates and other ion-exchange ceramics .
  • Suitable cations include silver, copper, zinc, mercury, tin, lead, gold, bismuth, cadmium, chromium and thallium ions, and combinations thereof, with silver, zinc and/or copper being preferred.
  • Either natural zeolites or synthetic zeolites can be used to make the zeolites used in the embodiments disclosed herein.
  • Zerolite is an aluminosilicate having a three dimensional skeletal structure that is represented by the formula: ⁇ 2 / ⁇ ⁇ AI 2 O 3 ⁇ YS1O 2 ⁇ Z3 ⁇ 40 wherein M represents an ion- exchangeable ion, generally a monovalent or divalent metal ion, n represents the atomic valency of the (metal) ion, X and Y represent coefficients of metal oxide and silica respectively, and Z represents the number of water of crystallization.
  • Examples of such zeolites include A-type zeolites, X-type zeolites, Y-type zeolites, T-type zeolites, high-silica zeolites, sodalite, and others.
  • silicate materials such as metal doped phosphate glass, bioactive glass such as 45S5 and BG can be processed to deliver a suitable dose of antimicrobial cations .
  • PEEK is a high melting point material that has a melting point of approximately 340°C and must be processed at 360°C to 400°C to enable incorporation of metal zeolite powders and extruding or molding of the composite blend. At these high temperatures, release of any entrapped moisture can cause the formation of voids in the polymer melt. This can contribute to decomposition of the PEEK polymer and to oxidation of metals incorporated into the zeolite antimicrobial, reducing antimicrobial efficacy. Additionally, presence of voids can significantly degrade the properties of the final product. For material produced for load-bearing spinal implants, the minimization of the size and number of any voids is critical in maintaining the mechanical properties of the final product.
  • the silver zeolite powder should be heated to about 400°C at atmospheric pressure, and held there for sufficient time for the bound water to be released. If the powder is spread thinly, moisture release will be more efficient, and a holding time of 30 to 60 minutes is suitable.
  • the silver zeolite can also be dried at lower temperatures under reduced pressure. It is preferable that the composite blend components be dried in a clean environment to less than 0.1% moisture by weight prior to processing. Moreover, it is imperative to maintain the material in an anhydrous environment prior to and during processing.
  • the antimicrobial powder is extremely hygroscopic, requiring the material to be sealed in its original packaging prior to any usage. Exposure to ambient air has to be minimal during pre-blending operations. As an added precaution, the feeder powder hopper needs to be purged with dry nitrogen immediately before and after loading.
  • the PEEK material should be dried between 120°C-130°C for 12 hours (or at a time/temperature equivalent) before running any compounding operation. This ensures that the residual moisture of the PEEK pellets is less than 0.1% moisture by weight prior to processing.
  • Post-Processed Packaging The materials need to be packaged in moisture barrier bags immediately after compounding.
  • twin-screw extruder can be utilized for blending PEEK with required additives.
  • the additive is gravimetrically metered into molten PEEK just prior to entering the extruder screws to obtain the desire additive loading.
  • twin-screw extrusion improves filler distribution and wet-out, and results in a more reproducible rheological behavior.
  • One suitable extruder is a Leistritz ZSE twin screw extruder .
  • Near-net shaped compounded PEEK blanks suitable for secondary machining operations can be produced using the compression molding process.
  • Compression molding is a method of molding preheated compounded PEEK polymer pellets or pre-forms into predefined shapes in pressurized, heated mold cavities.
  • Compression molding is a high-volume, high- pressure method suitable for molding complex shapes. This process wastes relatively little material when compared to machining devices from extruded rods.
  • PEEK implants can be manufactured to final shape by removing material with machining process such as turning, boring, drilling, milling, broaching, sawing, shaping, planing and/or reaming. These machining processes can be manual or automated through the use of computer controlled machining centers .
  • the thermal conductivity of all polymeric materials is lower than that of metals, so heat build-up during machining is rapid. A cleaner cut and more open surface can be achieved if the bit is cooled and run at a slower rate.
  • Machined PEEK surfaces can smear and "skin" if the PEEK surface temperature significantly rises while the material is being machined into implants, possibly affecting the release of cations.
  • a clean cut and "open" surface structure is desired.
  • One method to achieve the desired surface finish is to cool the cutting tool with cold, clean compressed air in conjunction with optimized tool cutting speed and feed rates.
  • cooling rates can have a profound effect on the crystallinity of PEEK, which may be critical to optimize the rate of release of metallic ions. By adjusting the cooling rate during fabrication, the percent crystallinity of the implant material was carefully controlled .
  • Finished or significantly finished compounded PEEK devices can be manufactured using the injection molding process.
  • the injection molding process produces parts from compounded PEEK polymers by feeding compounded PEEK pellets into a heated barrel (400°C) where the molten compounded PEEK is mixed and forced into a heated mold cavity that is maintained at temperatures between about 175°C and 205°C. Once injected into to the mold, the molten compounded PEEK cools to a temperature below 343°C and hardens to the shape of the mold cavity.
  • the desired temperature between about 175°C to 205°C set- point of the molds, significant increases in part feature and tolerance control and minimization of surface skinning can be achieved.
  • the amount of metal zeolite incorporated into the resin should also be an amount effective for promoting antimicrobial activity; e.g., a sufficient amount so as to prevent or inhibit the growth and eradicate bacterial and fungal organisms.
  • incorporation of significant quantities of metal zeolites into the peek polymer melt can affect the viscosity and rheology of the composition. Therefore, a processing window was established that allowed for sufficient zeolite to be loaded without adversely affecting the bulk properties of the final product .
  • Suitable amounts of zeolite in the resin range from about 0.01 to 20.0 wt . % .
  • Optimal loading was found to range from 0.1 to about 10.0 wt . % .
  • the tightly controlled and monitored dimensions of the pellets produced from the optimal loading conditions are shown below in Table I .
  • the finished pellet color is an important indicator if severe oxidation occurred or moisture came into contact with the metal ions during the high temperature process. Pure PEEK is light tan in color while properly processed zeolite containing PEEK is brown in color. In cases where oxidation has occurred, the silver will rapidly darken to a dark brown or black color.
  • SEM Scanning electron micrographs
  • Pyrolysis was utilized for quantitative determination of the loading of silver metal zeolite.
  • a small accurately weighed sample of the PEEK/silver zeolite composite was placed in a ceramic crucible and burned with a propane torch. While plain PEEK burns away completely leaving no residue using this method, PEEK loaded with metal zeolites will burn off and leave behind a powdery residue.
  • the amount of silver zeolite loading can then be determined gravimetrically . The amount of silver present can be confirmed by extracting the silver from the residue and determining the amount of silver in the extraction solution by graphite furnace AA or ICP.
  • the elutable ionic silver content from samples with different loading rates was determined by chemical analysis using graphite furnace atomic absorption spectroscopy. l"xl" sample coupons were immersed into 40 ml of 0.8% sodium nitrate solution for a duration of 24 hours. The amount of silver eluted from different loadings is listed in Table II.
  • Elution of other antimicrobial metals can be determined similarly .
  • PEEK implants Because of PEEK' s radiolucent properties implanted devices made from PEEK do not show up well in X-ray images. Thus, identification of the precise location and integrity of the implant and observation of other important characteristics from X-rays can be difficult.
  • One method that has been used to overcome this drawback is the addition of barium sulfate to the compounding mix. Although devices can be radiopaque due to the addition of barium sulfate to PEEK, the addition of the required amounts of barium sulfate for the desired radiopacity tends to weaken the strength of the resulting device.
  • an implant made from a composition of barium sulfate and PEEK provides an undesirable tradeoff between the desired mechanical properties of the device and its radiopacity.
  • the materials disclosed herein display radiopaque properties even at low loading levels of silver zeolite when viewed under x-ray. This is an important additional benefit that can be derived without sacrificing antimicrobial effectiveness or mechanical integrity of the material .
  • Zeolite at the surface of the implant can significantly increase osteoblast cell attachment due to the presence of negatively charged silicates present in the zeolites.
  • a significant drawback of PEEK products oftentimes is the lack of cell adhesion at the implant site due to the inherent inertness of PEEK. This problem can be suitably alleviated through the availability of by negatively charged silicates at the implant surface.
  • the zeolite structure is inherently negatively charged. These silicates attract proteins containing the RGD peptide sequence with the correct confirmation, leading to the attachment and proliferation of bone forming osteoblast cells. This starts a cascading process that eventually results in significant bone growth.
  • PEEK is very impermeable to moisture so only material in the surface layer no deeper than the diameter of a zeolite particle will be accessible for silver elution. If the silver in this region were deactivated or otherwise converted into insoluble complexes the materials might well be ineffective as antimicrobial materials. So process conditions need to be carefully monitored and followed to maintain silver effectiveness on the implant surface. Effectiveness can be monitored quantitatively by measuring the elutable silver using an ICP and ensuring that the level is well above the reported minimum biofilm growth inhibitory concentration of 0.1 ppm of silver. 20 ppb silver has been shown to be active in the lab and formulations show antimicrobial activity below 5 ppb. Moreover, while the bulk solution concentration may be 5 ppb, the activity of cations close to the surface must necessarily be better.
  • Surface color can also be used as a qualitative measure for monitoring process conditions. Deactivated or otherwise converted silver will change color from brown to black or a mixture of black-brown.
  • surface roughness can be optimized to improve osteogenic properties of the implant.
  • In-vitro studies have shown that all parameters (adhesion, proliferation, alkaline phosphatase activity, synthesis of bone matrix proteins and mineralization) effecting bone growth appear to be influenced by the surface finish of the material.
  • Common manufacturing techniques such as abrasive blasting (bead blasting, sandblasting, sodablasting, cryogenic CO 2 blasting etc.), scraping or sanding with inert materials can be utilized to control the surface roughness to optimize both silver elution and cell growth.
  • Atomic force microscopy (AFM) or Profilometry can be utilized to calculate the average surface roughness in nanometers and this value can be correlated to bone growth parameters from vitro cell testing results to get the optimum range of surface roughness.
  • AFM Atomic force microscopy
  • Profilometry can be utilized to calculate the average surface roughness in nanometers and this value can be correlated to bone growth parameters from vitro cell testing results to get the
  • Figure 1 A specific example of the design is shown in Figure 1. As can be seen from the figure, the columnar design allows for a significant increase in surface area compared to a monolithic construction. This leads to a significantly enhanced silver elution profile as well as increasing the pathways for vascularization.
  • the PEEK can be made porous with suitable porosities including porosities between 50% and 85% by volume.
  • Porosity can be imparted using a pore forming agent such as sodium chloride, to create a porous polymer comprising a plurality of interconnected pores, by processes known in the art.
  • Average pore size is generally greater than 180 microns in diameter, suitably between about 300 and about 700 microns.
  • the PEEK can be reinforced with a reinforcing material such as ceramic or carbon fiber.
  • a reinforcing material such as ceramic or carbon fiber.
  • This can be produced by dispersing the reinforcing material in the PEEK polymer matrix, such as by twin screw compounding of implantable PEEK polymer with carbon fibers.
  • the resulting carbon fiber-reinforced product can be used to direct injection mold final devices and near net shapes, or it can be extruded into stock shapes for machining.
  • the incorporation of fibers or other suitable reinforcing material (s) provides high wear resistance, a Young's modulus of 12 GPa (matching the modulus of cortical bone) and providing sufficient strength to permit its use in very thin implant designs which distribute the stress more efficiently to the bone.
  • the amount of reinforcing material such as carbon fiber incorporated into the PEEK can be varied, such as to modify the Young' s modulus and flexural strength. One suitable amount is 30 wt . % carbon fiber.

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Abstract

La présente invention concerne des procédés permettant de fabriquer des dispositifs médicaux implantables, de préférence avec du polyétheréthercétone (en anglais PolyEtherEtherKetone ou PEEK), dotés de propriétés antimicrobiennes. On produit cet effet antimicrobien en ajoutant des particules de céramique contenant des ions métalliques antimicrobiens dans la résine de PEEK fondue, qu'on laisse ensuite refroidir et prendre dans sa forme définitive obtenue par moulage par injection, découpage et usinage ou par d'autres techniques.
PCT/US2010/059868 2009-12-11 2010-12-10 Procédé de fabrication d'implants antimicrobiens en polyétheréthercétone Ceased WO2011072212A2 (fr)

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RU2012129171/15A RU2526168C2 (ru) 2009-12-11 2010-12-10 Способ получения противомикробных имплантатов из полиэфирэфиркетона
CN201080063584.7A CN102834122B (zh) 2009-12-11 2010-12-10 制备聚醚醚酮抗微生物植入物的方法
EP10836743.4A EP2512538B1 (fr) 2009-12-11 2010-12-10 Procédé de fabrication d'implants antimicrobiens en polyétheréthercétone
US13/512,702 US8821912B2 (en) 2009-12-11 2010-12-10 Method of manufacturing antimicrobial implants of polyetheretherketone
BR112012016027-3A BR112012016027B1 (pt) 2009-12-11 2010-12-10 método de produção de implantes antimicrobianos de polieteretercetona
US13/653,896 US8840914B2 (en) 2009-12-11 2012-10-17 Method of manufacturing antimicrobial implants of polyetheretherketone
US14/471,329 US9132576B2 (en) 2009-12-11 2014-08-28 Method of manufacturing antimicrobial implants of polyetheretherketone

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US61/285,719 2009-12-11
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US13/653,896 Continuation US8840914B2 (en) 2009-12-11 2012-10-17 Method of manufacturing antimicrobial implants of polyetheretherketone
US14/471,329 Continuation US9132576B2 (en) 2009-12-11 2014-08-28 Method of manufacturing antimicrobial implants of polyetheretherketone

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RU2012129171A (ru) 2014-01-20
EP2512538A2 (fr) 2012-10-24
US8840914B2 (en) 2014-09-23
US20130004585A1 (en) 2013-01-03
RU2526168C2 (ru) 2014-08-20
CN102834122B (zh) 2015-03-11
BR112012016027B1 (pt) 2019-01-15
BR112012016027A2 (pt) 2018-05-29
EP2512538A4 (fr) 2013-09-25
WO2011072212A3 (fr) 2011-11-17
US20130037991A1 (en) 2013-02-14
CN102834122A (zh) 2012-12-19
US9132576B2 (en) 2015-09-15
EP2512538B1 (fr) 2017-02-22
US8821912B2 (en) 2014-09-02

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