Fiber-microsphere bioresorbable composite scaffold for wound healing

1. A reduced pressure tissue treatment apparatus for applying a reduced pressure tissue treatment to a tissue site comprising:

a composite scaffold formed from porous materials comprising:

a first layer of porous material selected from one of a layer of bioresorbable microspheres and a layer of bioresorbable fibers;

a second layer of porous material selected from the other of said layer of bioresorbable microspheres and said layer of bioresorbable fibers, wherein a substantially planar surface of the first layer is joined to a substantially planer surface of the second layer at an interface, and wherein one of the first layer of material and the second layer of material are adapted to be located substantially adjacent to the tissue site; and

wherein the porous materials of the first layer and the second layer include a plurality of flow channels formed by openings in the porous materials of the first layer and the second layer, each layer having pore sizes from about 50 microns to about 600 microns, wherein the first layer and the second layer are in fluid communication with adjacent openings to distribute reduced pressure through the composite scaffold to the tissue site while minimizing compression of the composite scaffold to prevent occlusion of the pores when reduced pressure is applied to the composite scaffold; and

a reduced pressure source fluidly connected to the composite scaffold for supplying reduced pressure to the composite scaffold.

2. The reduced pressure tissue treatment apparatus of claim 1 , wherein the composite scaffold further comprises:

additional layers of porous material selected from one of said layer of bioresorbable microspheres and said layer of bioresorbable fibers.

3. The reduced pressure tissue treatment apparatus of claim 1 , wherein said first layer of porous material and said second layer of porous material are selected from the group consisting of bioresorbable material may be made from polylactide (“PLA”) (both L-lactide and D,L-lactide), copolymer of Poly(L-lactide-co-D,L-lactide), polyglycolic acid (“PGA”), alpha esters, saturated esters, unsaturated esters, orthoesters, carbonates, anhydrides, ethers, amides, saccharides, polyesters, polycarbonates, polycaprolactone (“PCL”), polytrimethylene carbonate (“PTMC”), polydioxanone (“PDO”), polyhydroxybutyrate, polyhydroxyvalerate, polyorthoesters, polyphosphazenes, polyurethanes, collagen, hyaluronic acid, chitosan, hydroxyapatite, coralline apatite, calcium phosphate, calcium sulfate, carbonates, bioglass, allografts, autografts, mixtures, and co-polymers of these compounds.

4. The reduced pressure tissue treatment apparatus of claim 1 , wherein said first layer of porous material and said second layer of porous material are joined together by at least one of the following means bonding, adhesives, welding, fastening, and sintering.

5. The reduced pressure tissue treatment apparatus of claim 1 , wherein said first layer of porous material has a thickness of about 0.1 mm to about 1 mm and the second layer of porous material has a thickness of about 0.2 mm to about 1 mm.

6. The reduced pressure tissue treatment apparatus of claim 1 , wherein said layer of bioresorbable microspheres are sintered together.

7. The reduced pressure tissue treatment apparatus of claim 1 , wherein the openings of the plurality of flow channels are selected from the group consisting of pores, voids, apertures, and cells.

8. The reduced pressure tissue treatment apparatus of claim 1 , wherein the layer of bioresorbable fibers includes fibers comprising thread filaments.

9. The reduced pressure tissue treatment apparatus of claim 8 , wherein the fibers are continuous filaments or discrete elongated filaments.

10. The reduced pressure tissue treatment apparatus of claim 8 , wherein the fibers are microfibers.

11. The reduced pressure tissue treatment apparatus of claim 8 , wherein the fibers are natural filaments or synthetic filaments.

12. A reduced pressure tissue treatment apparatus for applying a reduced pressure tissue treatment to a tissue site comprising:

a first layer of porous material selected from one of a layer of bioresorbable microspheres and a layer of bioresorbable fibers;

a second layer of porous material selected from the other of said layer of bioresorbable microspheres and said layer of bioresorbable fibers, wherein a substantially planar surface of said first layer is joined to a substantially planer surface of said second layer at an interface, and wherein one of said first layer of material and said second layer of material are adapted to be located substantially adjacent to said tissue site;

a manifold located substantially over said first layer and said second layer in sealing communication with said tissue site to receive reduced pressure for the tissue site; and

wherein the porous materials of the first layer and the second layer include a plurality of flow channels formed by openings in the porous materials of the first layer and the second layer in fluid communication with adjacent openings to distribute a reduced pressure through said manifold to said tissue site, and wherein the openings of the plurality of flow channels are pores having pore sizes from about 50 microns to about 600 microns to minimize compression of the composite scaffold and prevent occlusion of the pores when reduced pressure is applied to the composite scaffold.

13. The reduced pressure tissue treatment apparatus of claim 12 , further comprising:

additional layers of porous material selected from one of said layer of bioresorbable microspheres and said layer of bioresorbable fibers located adjacent to one of said first layer of porous material and said second layer of porous material.

14. The reduced pressure tissue treatment apparatus of claim 12 , wherein said first layer of porous material and said second layer of porous material are selected from the group consisting of bioresorbable material may be made of polylactide (“PLA”) (both L-lactide and D,L-lactide), copolymer of Poly(L-lactide-co-D,L-lactide), polyglycolic acid (“PGA”), alpha esters, saturated esters, unsaturated esters, orthoesters, carbonates, anhydrides, ethers, amides, saccharides, polyesters, polycarbonates, polycaprolactone (“PCL”), polytrimethylene carbonate (“PTMC”), polydioxanone (“PDO”), polyhydroxybutyrate, polyhydroxyvalerate, polyorthoesters, polyphosphazenes, polyurethanes, collagen, hyaluronic acid, chitosan, hydroxyapatite, coralline apatite, calcium phosphate, calcium sulfate, carbonates, bioglass, allografts, autografts, mixtures, and co-polymers of these compounds.

15. A process of making a fiber-microsphere composite scaffold comprising:

preparing a first layer of porous material selected from one of a layer of bioresorbable microspheres and a layer of bioresorbable fibers having a plurality of flow channels formed by openings in the porous material of the first layer in fluid communication with adjacent openings to distribute reduced pressure, and wherein the openings in the porous material have pore sizes from about 50 microns to about 600 microns to minimize compression of the composite scaffold and prevent occlusion of the pores when reduced pressure is applied to the composite scaffold;

preparing a second layer of porous material selected from the other of said layer of bioresorbable microspheres and said layer of bioresorbable fibers having a plurality of flow channels formed by openings in the porous material of the second layer in fluid communication with adjacent openings to distribute reduced pressure, and wherein the openings in the porous material have pore sizes from about 50 microns to about 600 microns to minimize compression of the composite scaffold and prevent occlusion of the pores when reduced pressure is applied to the composite scaffold;

orienting said first layer of porous material and said second layer of porous material

joining a substantially planar surface of the first layer is to a substantially planer surface of the second layer at an interface; and

finishing said fiber-microsphere composite scaffold.

16. The process for making a fiber-microsphere composite scaffold of claim 15 , further comprising:

preparing additional layers of porous material selected from one of said layer of bioresorbable microspheres and said layer of bioresorbable fibers.

17. The process for making a fiber-microsphere composite scaffold of claim 16 , further comprising:

joining said additional layers of porous material to said first layer of material and said second layer of material.

18. The process for making a fiber-microsphere composite scaffold of claim 16 , wherein finishing said fiber-microsphere composite scaffold comprises:

processing said fiber-microsphere composite scaffold by at least one of shaping, trimming, cutting, forming, sterilizing, and packaging.

19. The process for making a fiber-microsphere composite scaffold of claim 15 , wherein said joining comprises at least one process selected from the group consisting of welding, bonding, adhering, gluing, ultrasonic point-bonding, fastening, and pressing.

20. A reduced pressure tissue treatment apparatus for applying a reduced pressure tissue treatment to a tissue site comprising:

a composite scaffold formed from porous materials comprising:

a first layer of porous material selected from one of a layer of bioresorbable microspheres and a layer of bioresorbable fibers;

a second layer of porous material selected from the other of said layer of bioresorbable microspheres and said layer of bioresorbable fibers, wherein a substantially planar surface of the first layer is joined to a substantially planer surface of the second layer at an interface, and wherein one of the first layer of material and the second layer of material are adapted to be located substantially adjacent to the tissue site; and

wherein the porous materials of the first layer and the second layer include a plurality of flow channels formed by openings in the porous materials of the first layer and the second layer, each layer having pore sizes from about 400 microns to about 600 microns, wherein the first layer and the second layer are in fluid communication with adjacent openings to distribute reduced pressure through the composite scaffold to the tissue site, while minimizing compression of the composite scaffold to prevent occlusion of the pores when reduced pressure is applied to the composite scaffold; and

a reduced pressure source fluidly connected to the composite scaffold for supplying reduced pressure to the composite scaffold.

21. A reduced pressure tissue treatment apparatus for applying a reduced pressure tissue treatment to a tissue site comprising:

a first layer of porous material selected from one of a layer of bioresorbable microspheres and a layer of bioresorbable fibers;

a second layer of porous material selected from the other of said layer of bioresorbable microspheres and said layer of bioresorbable fibers, wherein a substantially planar surface of said first layer is joined to a substantially planer surface of the said second layer at an interface one of said first layer of material and said second layer of material are adapted to be located substantially adjacent to said tissue site;

a manifold located substantially over said first layer and said second layer in sealing communication with said tissue site to receive reduced pressure for the tissue site; and

wherein the porous materials of the first layer and the second layer include a plurality of flow channels formed by openings in the porous materials of the first layer and the second layer in fluid communication with adjacent openings to distribute a reduced pressure through said manifold to said tissue site, and wherein the openings of the plurality of flow channels are pores having pore sizes from about 400 microns to about 600 microns to minimize compression of the composite scaffold and prevent occlusion of the pores when reduced pressure is applied to the composite scaffold.