Crosslinked Orthopedic Biomaterial Composite Manufacturing
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Solution Overview
Problem
Conventional orthopedic implants made from metals, ceramics, or polymers lack the optimal combination of manufacturability, mechanical strength, and osteointegration, particularly when resistance to long-term cyclical loading is required.
Innovation Solution
A method of manufacturing surgical implants involving the polymerization of a bifunctional monomer with a long-chain acrylic to form a high-strength copolymer, dispersion of ceramic particles in the copolymer to create a composite biomaterial, and subsequent crosslinking to stabilize the ceramic particles and enhance mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional materials (metals, ceramics, or polymers) are used for orthopedic implants, then manufacturability and basic mechanical properties are achieved, but mechanical strength and osteointegration are insufficient
Solution Approach 1:
The patent uses a composite material system consisting of a polymeric base material reinforced with ceramic particles (such as hydroxyapatite, tricalcium phosphate, or bioglass). This composite structure combines the manufacturability and biocompatibility of polymers with the high strength and osteoconductivity of ceramics, resolving the contradiction between mechanical strength and ease of manufacture.
Solution Approach 2:
The patent modifies the polymer material parameters by incorporating ceramic fillers and controlling the polymer's crystallinity and crosslinking density. These parameter changes enhance the mechanical strength and osteointegration properties while maintaining the manufacturability advantages of polymeric materials.
2Ease of manufacture
If polymer materials are used for orthopedic implants, then manufacturability is improved, but resistance to long-term cyclical loading is insufficient
Solution Approach 1:
The patent creates a composite polymer-ceramic material where the ceramic particles reinforce the polymeric matrix against cyclical loading. The ceramic reinforcement provides fatigue resistance while the polymeric base maintains manufacturability, solving the reliability-manufacturing contradiction.
Solution Approach 2:
The patent introduces ceramic particles at specific locations within the polymer matrix to provide localized reinforcement where mechanical stress occurs during cyclical loading. This local quality enhancement improves fatigue resistance without compromising overall manufacturability.
3Strength
If ceramic particles are added to polymer to enhance strength, then mechanical properties improve, but manufacturing complexity increases
Solution Approach 1:
The patent merges the ceramic particles with the polymeric matrix during the same manufacturing process, creating a homogeneous composite material. This combining approach enhances mechanical strength while avoiding the additional complexity of separate manufacturing steps for ceramic integration.
Solution Approach 2:
The patent incorporates ceramic particles into the polymer matrix during the polymerization or molding process itself, rather than adding them as a separate post-processing step. This preliminary action simplifies manufacturing by integrating multiple functions into a single process.
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 method results in surgical implants with improved mechanical strength, osteointegration, and manufacturability, making them suitable for load-bearing applications while maintaining stability and resistance to cyclical loading.
Implementation Method 1
polymerizing a bifunctional monomer with a long-chain acrylic to form a high-strength copolymer
Implementation Method 2
crosslinking the formed implant to form the surgical implant, thereby stabilizing the ceramic particles in the surgical implant
Implementation Method 3
crosslinking is initiated by applying heat, pressure, irradiation (such as gamma irradiation, ultraviolet irradiation, microwave radiation, electron beam irradiation, infrared radiation, and combinations thereof)
Implementation Method 4
crosslinking is initiated by applying heat, pressure, irradiation (such as gamma irradiation, ultraviolet irradiation, microwave radiation, electron beam irradiation, infrared radiation, and combinations thereof)
Data Source
AI summary
Provided herein are surgical implants and methods of manufacturing the surgical implants. Generally, the method includes polymerizing a bifunctional monomer with a long-chain acrylic to form a high-strength copolymer, dispersing a plurality of ceramic particles in the copolymer to form a composite biomaterial, forming the composite biomaterial into an implant, and crosslinking the formed implant to form the surgical implant, thereby stabilizing the ceramic particles in the surgical implant.