Porous biocompatible polymer material and methods
View Patent ↗Embodiments described include devices and methods for forming a porous polymer material. Devices disclosed and formed using the methods described include a spacer for spinal fusion, craniomaxillofacial (CMF) structures, and other structures for tissue implants.
1. A porous structure for promoting bony ingrowth, comprising:
a network of polymer granules, the polymer granules having a microporous surface structure and being bonded together at contact points; and
a plurality of interstitial spaces between the polymer granules,
wherein the polymer granules comprise polyetheretherketone.
2. The porous structure of claim 1 , wherein the porous structure is a spacer for spinal fusion.
3. The porous structure of claim 1 , wherein the porous structure is a craniomaxillofacial (CMF) structure.
4. The porous structure of claim 1 , wherein the porous structure is a scaffold structure.
5. The porous structure of claim 1 , further comprising
a biologically active substance infused throughout the plurality of interstitial spaces; and
a coating configured to allow controlled release of the biologically active substance upon implantation of the porous structure into a patient.
6. The porous structure of claim 1 , wherein the microporous surface structure has a mean pore size of 0.1 μm to 100 μm.
7. The porous structure of claim 1 , further comprising a solid core structure bonded between two porous endcaps wherein each of the endcaps includes the network of polymer granules and the plurality of interstitial spaces between the polymer granules.
8. The porous structure of claim 1 , wherein the interstitial spaces have a mean pore size from 5 μm to 5000 μm.
9. The porous structure of claim 8 , wherein the mean pore size is from 100 μm to 500 μm.
10. The porous structure of claim 1 , further comprising a radiopaque material incorporated in the network of polymer granules, the radiopaque material configured to provide selective areas of radiopacity.
11. The porous structure of claim 10 , wherein the radiopaque material is configured to mechanically reinforce the porous structure.
12. The porous structure of claim 1 , wherein the interstitial spaces are infused with a biologically active substance.
13. The porous structure of claim 12 , wherein the biologically active substance is blood or bone marrow.
14. The porous structure of claim 12 , wherein the biologically active substance is further comprising an allogenic biological substance.
15. The porous structure of claim 12 , wherein the biologically active substance is a growth factor.
16. The porous structure of claim 15 , wherein the growth factor is a bone morphogenetic protein or a platelet-derived growth factor.
17. The porous structure of claim 1 , further comprising a solid structure coupled to the network of polymer granules at a porous/solid interface.
18. The porous structure of claim 17 , wherein the network of polymer granules is mechanically fastened to the solid structure.
19. The porous structure of claim 18 , wherein the network of polymer granules is mechanically fastened to the solid structure with an interference fit, a bayonette fastener or tabs that fit into corresponding slots.
20. The porous structure of claim 17 , wherein the network of polymer granules is bonded on at least two sides with the solid structure.
21. The porous structure of claim 20 , further including a holding feature formed as part of the solid structure to facilitate placement of the combined structure.
22. The porous structure of claim 20 , wherein the solid structure comprises polyetheretherketone.
23. The porous structure of claim 1 , further comprising
a porous main body that includes the network of polymer granules and the plurality of interstitial spaces between the polymer granules; and
a solid band attached to and positioned about the porous main body.
24. The porous structure of claim 23 , wherein the porous main body is mechanically connected to the solid band with an interference fit.
25. The porous structure of claim 23 , wherein the porous main body is thermally bonded to the solid band.
26. The porous structure of either of claim 24 or 25 , wherein the solid band is annularly position about the porous main body.
27. The porous structure of claim 26 , further comprising a radiopaque material incorporated in the porous main body, the radiopaque material configured to provide selective areas of radiopacity.
28. A porous structure for promoting bony ingrowth, comprising:
a network of polymer granules, the polymer granules having a microporous surface structure and being bonded together at contact points;
a plurality of interstitial spaces between the polymer granules; and
a solid core structure bonded between two porous endcaps, wherein each of the endcaps includes the network of polymer granules and the plurality of interstitial spaces between the polymer granules.
29. The porous structure of claim 28 , wherein the porous structure is a spacer for spinal fusion.
30. The porous structure of claim 28 , wherein the porous structure is a scaffold structure.
31. The porous structure of claim 28 , further including a holding feature formed as part of the solid structure to facilitate placement of the combined structure.
32. The porous structure of claim 28 , wherein the polymer granules comprise polyetheretherketone.
33. The porous structure of claim 28 , further comprising
a biologically active substance infused throughout the plurality of interstitial spaces; and
a coating configured to allow controlled release of the biologically active substance upon implantation of the porous structure into a patient.
34. The porous structure of claim 28 , wherein the microporous surface structure has a mean pore size of 0.1 μm to 100 μm.
35. The porous structure of claim 28 , wherein the solid core structure comprises polyetheretherketone.
36. The porous structure of claim 28 , wherein the solid core structure is thermally bonded to the two porous endcaps.
37. The porous structure of claim 28 , wherein the two porous endcaps are mechanically fastened to the solid structure.
38. The porous structure of claim 37 , wherein the two porous endcaps are mechanically fastened to the solid structure with an interference fit, a bayonette fastener or tabs that fit into corresponding slots.
39. The porous structure of claim 28 , wherein the interstitial spaces have a mean pore size from 5 μm to 5000 μm.
40. The porous structure of claim 39 , wherein the mean pore size is from 100 μm to 500 μm.
41. The porous structure of claim 28 , further comprising a radiopaque material incorporated in the network of polymer granules, the radiopaque material configured to provide selective areas of radiopacity.
42. The porous structure of claim 41 , wherein the radiopaque material is configured to mechanically reinforce the porous structure.
43. The porous structure of claim 28 , wherein the interstitial spaces are infused with a biologically active substance.
44. The porous structure of claim 43 , wherein the biologically active substance is blood or bone marrow.
45. The porous structure of claim 43 , wherein the biologically active substance further comprises an allogenic biological substance.
46. The porous structure of claim 43 , wherein the biologically active substance is a growth factor.
47. The porous structure of claim 46 , wherein the growth factor is a bone morphogenetic protein or a platelet-derived growth factor.
48. A porous structure for promoting bony ingrowth, comprising:
a network of polymer granules, the polymer granules having a microporous surface structure and being bonded together at contact points;
a plurality of interstitial spaces between the polymer granules; and
a solid structure coupled to the network of polymer granules at a porous/solid interface, wherein the network of polymer granules is bonded on at least two sides with the solid structure, and
wherein the solid structure comprises polyetheretherketone.
49. The porous structure of claim 48 , wherein the porous structure is a spacer for spinal fusion.
50. The porous structure of claim 48 , wherein the porous structure is a scaffold structure.
51. The porous structure of claim 48 , further including a holding feature formed as part of the solid structure to facilitate placement of the combined structure.
52. The porous structure of claim 48 , wherein the polymer granules comprise polyetheretherketone.
53. The porous structure of claim 48 , further comprising
a biologically active substance infused throughout the plurality of interstitial spaces; and
a coating configured to allow controlled release of the biologically active substance upon implantation of the porous structure into a patient.
54. The porous structure of claim 48 , wherein the microporous surface structure has a mean pore size of 0.1 m to 100 μm.
55. The porous structure of claim 48 , wherein the solid core structure comprises polyetheretherketone.
56. The porous structure of claim 48 , wherein the network of polymer granules is thermally bonded to the solid structure.
57. The porous structure of claim 48 , wherein the network of polymer granules is mechanically fastened to the solid structure.
58. The porous structure of claim 57 , wherein the network of polymer granules is mechanically fastened to the solid structure with an interference fit, a bayonette fastener or tabs that fit into corresponding slots.
59. The porous structure of claim 48 , wherein the interstitial spaces have a mean pore size from 5 μm to 5000 μm.
60. The porous structure of claim 59 , wherein the mean pore size is from 100 μm to 500 μm.
61. The porous structure of claim 48 , further comprising a radiopaque material incorporated in the network of polymer granules, the radiopaque material configured to provide selective areas of radiopacity.
62. The porous structure of claim 61 , wherein the radiopaque material is configured to mechanically reinforce the porous structure.
63. The porous structure of claim 48 , wherein the interstitial spaces are infused with a biologically active substance.
64. The porous structure of claim 63 , wherein the biologically active substance is blood or bone marrow.
65. The porous structure of claim 63 , wherein the biologically active substance is further comprising an allogenic biological substance.
66. The porous structure of claim 63 , wherein the biologically active substance is a growth factor.
67. The porous structure of claim 66 , wherein the growth factor is a bone morphogenetic protein or a platelet-derived growth factor.