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. An orthopedic implant comprising:
a composite body comprising a plurality of thermoplastic polymers, the composite body including a first porous portion and a second solid portion bonded to the first porous portion;
wherein the first porous portion comprises a first thermoplastic polymer of the plurality of thermoplastic polymers that comprises a PEAK family polymer and the second solid portion comprises a second thermoplastic polymer of the plurality of thermoplastic polymers that comprises polyethylene; and,
wherein the first porous portion comprises a network of granules of the first thermoplastic polymer bonded together a contact points and defining a plurality of interstitial spaces between the network of granules.
2. The orthopedic implant of claim 1 , wherein the second thermoplastic polymer further comprises PAEK family, PCL, PLA, PGA, polyphenylene, polyphenylsulphone, polysulphone, PET, polyurethane, or combinations thereof.
3. The orthopedic implant of claim 1 , wherein the PEAK family polymer is PEEK or carbon reinforced PEEK.
4. The orthopedic implant of claim 1 , wherein the network of granules are melt-bonded together at the contact points.
5. The orthopedic implant of claim 1 , wherein the interstitial spaces have a pore size in the range 5 μm to 5000 μm.
6. The orthopedic implant of claim 1 , wherein the granules have an average size in the range of about 0.25 mm to about 1.0 mm.
7. The orthopedic implant of claim 1 , wherein the first porous portion has an average porosity of between about 30% to about 45%.
8. The orthopedic implant of claim 1 , wherein the first thermoplastic polymer further comprises PAEK family, PCL, PLA, PGA, polyphenylene, polyphenylsulphone, polysulphone, PET, polyethylene, polyurethane, or combinations thereof.
9. The orthopedic implant of claim 8 , wherein the first thermoplastic polymer further comprises PAEK family polymer.
10. The orthopedic implant of claim 9 , wherein the PAEK family polymer is PEEK, carbon reinforced PEEK, PEKK, PEK, or PEKEKK, or combinations thereof.
11. The orthopedic implant of claim 10 , wherein the PAEK family polymer is PEEK or carbon reinforced PEEK.
12. The orthopedic implant of claim 1 , wherein the second solid portion is configured in the shape of a solid core, a solid band, or a solid skin.
13. The orthopedic implant of claim 12 , wherein the second solid portion is configured in the shape of a solid skin.
14. The orthopedic implant of claim 1 , wherein each granule of the network of granules defines a polymer granule surface, and wherein each polymer granule surface defines a microporous surface porosity comprising a plurality of micropores.
15. The orthopedic implant of claim 14 , wherein the microporous surface porosity is in the range of about 0.1 μm to about 100 μm.
16. The orthopedic implant of claim 14 , wherein the polymer granule surface further comprises a coating powder on at least a portion of the polymer granule surface.
17. The orthopedic implant of claim 16 , wherein the coating powder comprises coating powder particles having a size in the range of 0.1 microns to 100 microns.