Bioactive load-bearing composites
Methods of preparing bioactive composites are described. Also described are methods of molding such composites. Shaped bodies comprising bioactive composites are further described.
1. A method of preparing a bioactive composite comprising:
(a) blending polyetheretherketone particles and bioactive glass particles to form a particle mixture, wherein the bioactive glass particles have an average particle size of 1 to 400 microns, and the polyetheretherketone particles have an average particle size of about 1 to about 400 microns in diameter, wherein the number of polyetheretherketone particles is greater than the number of bioactive glass particles;
(b) adding a polar organic solvent to the particle mixture to form a mixture containing a weight ratio of the polar organic solvent to the particle mixture of about 1:1 to about 4:1;
(c) agitating the mixture for a period of time and under conditions sufficient to achieve substantial homogeneity of the mixture; and
(d) removing substantially all of the polar organic solvent from the mixture.
2. The method of claim 1 wherein the bioactive glass particles are present in an amount of about 5-60% by weight of the particle mixture.
3. The method of claim 1 wherein the bioactive glass particles comprise combeite glass-ceramic.
4. The method of claim 1 wherein the ratio of polyetheretherketone particles to bioactive glass particles is between about 6:1 to about 10:1.
5. The method of claim 1 further comprising mixing at least one filler with the polyetheretherketone particles and the bioactive glass particles.
6. The method of claim 1 wherein the polar organic solvent contains less than about 5% by weight of water.
7. A method of preparing a bioactive shaped body comprising:
(a) blending polyetheretherketone particles and bioactive glass particles to form a particle mixture, wherein the bioactive glass particles have an average particle size of 1 to 400 microns, and the polyetheretherketone particles have an average particle size of about 1 to about 400 microns in diameter, wherein the number of polyetheretherketone particles is greater than the number of bioactive glass particles;
(b) adding a nonaqueous, polar organic solvent to the particle mixture to form a mixture containing a weight ratio of solvent to particle mixture of about 1:1 to about 4:1;
(c) agitating the mixture for a time and under conditions sufficient to achieve substantial homogeneity of the mixture;
(d) removing substantially all of the solvent from the mixture to obtain a substantially homogeneous particle mixture; and
(e) shaping the substantially homogeneous particle mixture under conditions of heat and pressure sufficient to provide an integral shaped body.
8. The method of claim 7 wherein the shaping comprises heating to a temperature sufficient to melt at least one component of the mixture.
9. The method of claim 7 wherein the shaping comprises applying pressure.
10. The method of claim 7 further comprising holding the mixture for a time and at a temperature sufficient to effect curing.
11. The method of claim 7 further comprising cooling the shaped body.
12. The method of claim 7 further comprising cooling the shaped body to at or below ambient temperature.