Foamed PEEK Implant Surface for Bone Integration
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Solution Overview
Problem
Conventional artificial bone implants face challenges such as mechanical property mismatch with natural bone, stress shielding, and inadequate integration due to differences in mechanical and biological properties, as well as limitations in forming porous structures with complex shapes and high strength requirements.
Innovation Solution
An article with a foamed surface comprising small and large open pores, made from engineering plastics like polyetheretherketone (PEEK) with embedded fibers, and a method involving pore formation using a foaming agent and coagulating solution to create a porous structure suitable for bone tissue integration, allowing for bioactive substance incorporation to enhance bone growth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If artificial bone is made of metal materials such as titanium alloy, then high strength is achieved, but stress shielding occurs due to differences in mechanical properties between the metal material and the surrounding bone
Solution Approach 1:
The patent changes the material parameters by using PEEK polymer with elastic modulus and strength values closer to natural bone, thereby reducing the mechanical property mismatch that causes stress shielding while maintaining sufficient structural strength for load-bearing applications
2Reliability
If artificial bone is made of bioceramics such as hydroxyapatite, then high biocompatibility and binding capability with natural bone are achieved, but weakness against external impact occurs
Solution Approach 1:
The patent employs composite material strategies by combining PEEK polymer with bioceramic particles or fibers, creating a material that exhibits both the high biocompatibility and bone-binding capability of ceramics and the toughness and impact resistance of the polymer matrix
3Strength
If artificial bone is made of polymer materials, then mechanical properties close to natural bone are achieved, but limited binding capability with native bone occurs
Solution Approach 1:
The patent applies local quality modification by creating a porous surface layer or coating on the polymer implant that provides bone-binding functionality, while the bulk polymer material maintains its favorable mechanical properties matching natural bone
Solution Approach 2:
The patent enhances binding capability by incorporating bioceramic particles, fibers, or coatings into the polymer matrix, creating a composite structure that combines the mechanical advantages of polymers with the bone-binding properties of ceramics
4Reliability
If porous structure is formed in artificial bone to facilitate bone tissue penetration, then binding capability with native bone is improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes porous materials with controlled pore size, distribution, and connectivity to facilitate bone tissue ingrowth and vascularization, improving biological integration while maintaining structural integrity
Solution Approach 2:
The patent incorporates pore-forming agents or creates porous structures during the manufacturing process itself, rather than requiring subsequent complex post-processing steps, thereby simplifying overall manufacturing while achieving the desired porous architecture for bone penetration
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 foamed surface article provides mechanical properties similar to bone, enables effective bone tissue penetration and integration, and supports high-strength applications without stress shielding, while the method allows for the production of implants with complex shapes without requiring expensive equipment.
Implementation Method 1
a foaming step of immersing the base with small pores in a foaming solution to make the plastic base swell and make the foaming agent foam
Implementation Method 2
a coagulating step of immersing the foamed base in a coagulating solution to coagulate the swollen plastic
Implementation Method 3
a foaming step of immersing the base with small pores in a foaming solution to make the plastic base swell
Data Source
AI summary
The objection of this invention is to provide an article with a foamed surface having a porous structure in the surface of a plastic base, an implant and a method of producing them. The article has a body and a superficial layer formed in a surface of the body, the layer including small-diameter and large-diameter pores, wherein part of the small-diameter and large-diameter pores are open pores which are open at the surface of the layer; the open pores have small open pores with an average diameter of 5 μm or less and large open pores with an average diameter from 10 to 200 μm; and the large open pores have an inner wall with passages connected with the small-diameter large-diameter pores. The implant is the article itself or the article with a bioactive substance in the layer thereof. The method provides an example of producing the article and implant.