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Methods for making oxidation resistant polymeric material

Inactive Publication Date: 2008-04-17
THE GENERAL HOSPITAL CORP +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0009] In another aspect, the invention provides methods of making cross-linked polymeric material comprising the steps of: a) placing a consolidated and cross-linked polymeric material in a pressure chamber; b) filling the chamber with an antioxidant, either in a neat form (about 100%) or in a solution such as a 50% mixture of the antioxidant and alcohol, such as ethanol; c) pressurizing the chamber to enhance diffusion of the antioxidant into the consolidated and cross-linked polymeric material; and d) annealing the antioxidant-doped cross-linked polymeric material in liquid or gaseous environment and under various temperature and pressure conditions, for example, in boiling water under atmospheric pressure. Cross-linked polymeric materials obtainable by these methods also are provided.

Problems solved by technology

However, such melting reduces the crystallinity of UHMWPE, which, in turn, decreases the yield strength, ultimate tensile strength, modulus, and fatigue strength of UHMWPE.
For certain applications that require high fatigue resistance, such highly crosslinked UHMWPE (that is irradiated and melted) may not be suitable; because, fatigue failure in the long term may compromise the performance of the medical device.

Method used

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  • Methods for making oxidation resistant polymeric material
  • Methods for making oxidation resistant polymeric material
  • Methods for making oxidation resistant polymeric material

Examples

Experimental program
Comparison scheme
Effect test

example 1

Consolidation of UHMWPE Resin Mixed with Vitamin E

[0202] Vitamin E was dissolved in ethanol to create a solution with 10% (w / v) vitamin E concentration. The vitamin E-ethanol solution was then dry-blended with GUR 1050 ultra-high molecular weight polyethylene (UHMWPE) resin. Two batches were prepared: one with vitamin E concentration of 0.1% (w / v) and the other with 0.3% (w / v). The vitamin E concentrations were measured after evaporation of ethanol. Both batches were than consolidated on a Carver laboratory bench pressed at a temperature of 230° C. in air. The consolidated blocks were discolored. The 0.1% (w / v) solution appeared dark yellow and the 0.3% (w / v) solution had a brown color. The discoloration was uniform throughout the consolidated UHMWPE blocks.

[0203] The discoloration was thought to be the result of the degradation of vitamin E when heated in presence of oxygen.

example 2

Discoloration of Vitamin E when Exposed to Heat in Air or in Vacuum

[0204] An experiment was carried out to determine if the vitamin E discoloration is due to exposure to air at elevated temperatures and if the discoloration could be avoided by heating vitamin E under vacuum.

[0205] One drop of vitamin E solution, as described herein, was placed on a laboratory glass slide. The glass slide was then heated in an air convection oven to 180° C. for 1 hour in air. The vitamin E changed its color to a dark brown. The discoloration was most probably due to the degradation of the vitamin E.

[0206] One drop of vitamin E was placed on a laboratory glass slide. The glass slide was then heated in a vacuum oven to 180° C. for 1 hour under vacuum. In contrast to heating in air, vitamin E showed no discernible color change following heating in vacuum. Therefore, in the absence of air or oxygen, heat treatment of vitamin E results in no discernable color change.

example 3

Consolidation of UHMWPE / Vitamin E in Anoxic Environment

[0207] Vitamin E is dissolved in ethanol to create a solution. GUR1050 polyethylene resin is degassed either in vacuum or is kept in an anoxic environment to substantially remove the dissolved oxygen. The vitamin E-ethanol solution is then dry-blended with GUR1050 polyethylene resin. Two batches are prepared, one with degassed GUR1050 and the other with the as-received GUR1050 polyethylene resin. The dry-blended mixtures are then separately consolidated on a Carver laboratory bench press. Consolidation can be carried out in an anoxic environment to minimize the discoloration of the consolidated stock.

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Abstract

The present invention relates to methods for making oxidation resistant medical devices that comprise polymeric materials, for example, ultra-high molecular weight polyethylene (UHMWPE). The invention also provides methods of making antioxidant-doped medical implants, for example, doping of medical devices containing cross-linked UHMWPE with vitamin E by diffusion, post-doping annealing, and materials used therein.

Description

[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60 / 569,624, filed May 11, 2004, which is incorporated by reference.FIELD OF THE INVENTION [0002] The present invention relates to methods for making oxidation resistant medical devices that comprise polymeric materials. Methods of doping polyethylene with an antioxidant (for example, vitamin E) post-doping annealing, and materials used therewith also are provided. BACKGROUND OF THE INVENTION [0003] Oxidation resistant cross-linked polymeric material, such as ultra-high molecular weight polyethylene (UHMWPE), is desired in medical devices because it significantly increases the wear resistance of the devices. The preferred method of crosslinking is by exposing the UHMWPE to ionizing radiation. However, ionizing radiation, in addition to crosslinking, also will generate residual free radicals, which are the precursors of oxidation-induced embrittlement. Melting during or after irradiation has been used ...

Claims

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Application Information

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IPC IPC(8): C08F10/02C08F2/46A61F2/00
CPCA61L27/16A61L27/505C08L23/06C08L23/10C08L27/06C08L2312/06C08L67/00C08L77/00B29C71/0009B29C71/02B29C71/04B29C2035/0877B29C2071/0027B29C2071/022
Inventor MURATOGLU, ORHUN K.SPIEGELBERG, STEPHEN H.
Owner THE GENERAL HOSPITAL CORP
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