Ceramic-Coated Polymer Scaffolds via Atomic Layer Deposition

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Solution Overview

Problem

Current porous polymer/ceramic composites for tissue engineering scaffolds face challenges in biocompatibility, toxicity, and mechanical properties, with potential nanoparticle migration and residual solvent issues, necessitating a material that is non-toxic, biocompatible, and promotes cell attachment and tissue regeneration.

Innovation Solution

A porous polymer scaffold with a ceramic coating, specifically aluminum oxide or titanium oxide, applied via atomic layer deposition, covering both external and internal surfaces to enhance biocompatibility and mechanical properties, facilitating cell attachment and tissue growth.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If porous polymer/ceramic composites are produced via incipient wetting methods (casting, porogen leaching, gas foaming), then porous structures can be formed, but toxic organic solvent residues remain and biocompatibility is compromised

Engineering Contradiction:

Improveporous structureVSAvoidtoxic organic solvent residues

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The patent changes the processing parameters by using water-based suspensions instead of organic solvents, and employs freeze-drying instead of conventional drying methods to eliminate toxic residues while maintaining porous structure formation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a safe processing environment by using water as the continuous phase instead of flammable organic solvents, and performs freeze-drying under vacuum conditions to prevent contamination and ensure biocompatibility

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Strength

If nanoparticle-containing scaffolds are used, then mechanical properties and bioactivity are enhanced, but nanoparticle migration and distribution via bloodstream may cause pathologies

Engineering Contradiction:

Improvemechanical propertiesVSAvoidnanoparticle migration

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent uses ceramic particles as intermediary reinforcement elements embedded in the polymer matrix, providing mechanical strength and bioactivity while the continuous polymer phase prevents nanoparticle migration and release into the bloodstream

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a composite material system where ceramic particles are dispersed in a polymer matrix, combining the mechanical properties and bioactivity of ceramics with the biocompatibility and continuity of the polymer phase to prevent particle migration

Inventive Principle:

Principle #40Composite materials

3Strength

If ceramic particles are dispersed in polymer matrix, then mechanical properties are reinforced, but nanoparticle migration and unknown pathologies may occur

Engineering Contradiction:

Improvemechanical reinforcementVSAvoidbiocompatibility

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent uses the polymer matrix as an intermediary that binds ceramic particles, providing mechanical reinforcement while preventing particle detachment and migration, thus ensuring biocompatibility and reliability

Inventive Principle:

Principle #24Intermediary (Mediator)

4Object-affected harmful factors

If pure polymer porous structures are used, then biocompatibility is achieved, but mechanical properties are adversely impacted

Engineering Contradiction:

ImprovebiocompatibilityVSAvoidmechanical properties

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent creates a composite material combining polymer and ceramic phases, where the polymer provides biocompatibility and the ceramic particles provide mechanical reinforcement, achieving both requirements simultaneously

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The ceramic-coated scaffolds demonstrate improved biocompatibility, enhanced cell adhesion, and tissue interaction, promoting effective tissue regeneration while minimizing toxicity and mechanical limitations, as evidenced by apatite formation and protein adsorption studies.

Implementation Method 1

the ceramic coating has a thickness of from about 1 to 100 nanometers and substantially covers the surfaces of the substrate material

Methodology Applied

Scientific EffectAtomic layer deposition: Chemical Vapour Deposition

Data Source

PatentUS9279120B2Implantable devices having ceramic coating applied via an atomic layer deposition method

Publication Date: 2016.03.08 THE REGENTS OF THE UNIVERSITY OF COLORADO

AI summary

Substrates coated with films of a ceramic material such as aluminum oxides and titanium oxides are biocompatible, and can be used in a variety of applications in which they are implanted in a living body. The substrate is preferably a porous polymer, and may be biodegradable. An important application for the ceramic-coated substrates is as a tissue engineering scaffold for forming artificial tissue.