Porous biocompatible polymer material and methods
Embodiments described include devices and methods for forming a porous polymer material. Devices disclosed and formed using the methods described a spacer for spinal fusion, craniomaxillofacial (CMF) structures, and other structures for tissue implants.
1. A porous structure for promoting tissue ingrowth, comprising:
a first solid portion bonded to a second porous portion, wherein the second porous portion comprises
a network of polymer granules-bonded together at contact points; the network of polymer granules defining a plurality of interstitial spaces between the polymer granules,
wherein each polymer granule of the network defines a polymer granule surface, and wherein each polymer granule surface defines a microporous surface porosity comprising a plurality of micropores on the polymer granule surface having a size range of about 0.1 microns to about 100 microns.
2. The porous structure of claim 1 , wherein the structure is a spacer for spinal fusion.
3. The porous structure of claim 1 , wherein the structure is a craniomaxillofacial (CMF) structure.
4. The porous structure of claim 1 , wherein the structure is a scaffold structure.
5. The porous structure of claim 1 , wherein the polymer granules comprise PCL, PLA, PGA, or a mixture thereof.
6. The porous structure of claim 1 , wherein the polymer granules comprise polyphenylene, self-reinforced polyphenylene, polyphenylsulphone, polysulphone, PET, polyethylene, polyurethane, or a mixture thereof.
7. The porous structure of claim 1 , further including a synthetic small molecule.
8. The porous structure of claim 1 , further including a hydrolytically degradable coating.
9. The porous structure of claim 1 , further including one or more radiopaque materials.
10. The porous structure of claim 1 , wherein the second porous portion includes one or more areas of selective compression.
11. The porous structure of claim 1 , wherein the interstitial spaces have a mean pore size of 5 μm to 5000 μm.
12. The porous structure of claim 1 , wherein the interstitial spaces have a mean pore size of 100 μm to 500 μm.
13. The porous structure of claim 1 , wherein the first solid portion comprises PAEK family polymers.
14. The porous structure of claim 1 , wherein the first solid portion comprises PEEK.
15. The porous structure of claim 1 , wherein the first solid portion comprises the same polymer as the second porous portion.
16. The porous structure of claim 1 , wherein the second porous portion has an average porosity of between about 30% to about 45%.
17. The porous structure of claim 1 , wherein the granules have an average size in the range of about 0.25 mm to about 1.0 mm.
18. The porous structure of claim 1 , wherein the second porous portion has a compressive strength in the range of 20 MPa to about 35 MPa.
19. The porous structure of claim 1 , wherein the second porous portion has a compressive strength in the range of 20 MPa to about 45 MPa.
20. The porous structure of claim 1 , wherein the polymer granules comprise PAEK family polymers.
21. The porous structure of claim 20 , wherein the first solid portion comprises PAEK family polymers.
22. The porous structure of claim 1 , wherein the polymer granules comprise PEEK.
23. The porous structure of claim 22 , wherein the first solid portion comprises PEEK.
24. The porous structure of claim 1 , further including a reinforcing structure.
25. The porous structure of claim 24 , wherein the reinforcing structure is incorporated through the porous structure.
26. The porous structure of claim 1 , further including a biological sub stance.
27. The porous structure of claim 26 , wherein the biological substance is autologous.
28. The porous structure of claim 26 , wherein the biological substance is allogenic.
29. The porous structure of claim 26 , wherein the biologically active substance is disposed within the interstitial spaces.
30. The porous structure of claim 26 , further comprising a coating of material configured to control the release of the biologically active substance.