Osteoconductive Fibrous Article Coating Method

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Solution Overview

Problem

Current methods for creating fibrous articles with osteoconductive properties for medical implants are complex and often result in variability and poor bioceramic particle bonding, leading to instability and loosening of implants.

Innovation Solution

A method involving coating fibers made from biocompatible, non-biodegradable polymers with a solution of coating polymer, followed by treatment with a dispersion of bioactive ceramic particles in a solvent compatible with the coating polymer, to achieve a bioceramic coating with particles partly embedded in the polymer layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If complex coating methods are used to achieve osteoconductive properties, then bioactivity is improved, but manufacturing complexity and variability increase

Engineering Contradiction:

Improvebioceramic particle bonding stabilityVSAvoidcoating process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by first coating fibers with a coating polymer solution, then treating with bioactive ceramic particle dispersion. This sequential preliminary preparation ensures proper surface conditioning before particle deposition, reducing variability and improving bonding stability without requiring overly complex processes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs parameter changes by controlling the solvent compatibility between coating polymer and ceramic particle dispersion medium. By selecting appropriate solvents and concentrations, the process achieves reliable particle bonding while maintaining manufacturing simplicity and consistency.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If bioactive ceramic particles are applied to fibrous articles, then osteoconductive properties are improved, but particle bonding stability deteriorates

Engineering Contradiction:

Improveosseointegration capabilityVSAvoidparticle bonding stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent creates a composite structure where bioactive ceramic particles are embedded in a coating polymer matrix. This composite approach ensures particles remain stably bonded to fibers while maintaining osteoconductive properties, as the polymer matrix provides mechanical anchoring and the ceramic particles provide biological activity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The coating polymer acts as an intermediary between the fiber and ceramic particles. It mediates the bonding interface, ensuring stable particle attachment while preserving osteoconductive functionality. The polymer solvent system facilitates proper particle incorporation without compromising bonding stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If coating polymer solution is applied before ceramic particles, then particle embedding is improved, but processing time increases

Engineering Contradiction:

Improveparticle embedding uniformityVSAvoidcoating process time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent merges the coating polymer application and ceramic particle deposition into a coordinated sequential process. By combining these steps with appropriate timing and using compatible solvents that allow continuous processing, the method achieves uniform particle embedding without excessive time loss, as the coating polymer layer is prepared immediately before particle application.

Inventive Principle:

Principle #5Merging (Combining)

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 a fibrous article with enhanced bioactivity and osseointegration, maintaining the mechanical properties necessary for medical applications, as demonstrated by good initial pull-out strength and biological activity in experiments.

Implementation Method 1

coating at least the fibers that will be in contact with bone upon use as an implant with a solution of a coating polymer to result in coated fibers having a coating polymer layer

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

treating the coated fibers with a dispersion of bioactive ceramic particles of particle size 0.01-10 μm in a treating solvent comprising a solvent for the coating polymer

Methodology Applied

Scientific EffectSolvation: Solvation

Data Source

PatentUS20250032679A1Method of making an osteoconductive fibrous article and a medical implant comprising such osteoconductive fibrous article

Publication Date: 2025.01.30 DSM IP ASSETS BV

AI summary

The disclosure relates to a method of making a bioactive coating on a fibrous article for use in a medical implant and implants comprising non-biodegradable fibers, a coating polymer layer formed from a non-biodegradable coating polymer on at least a portion of the fibers, and a bioactive coating disposed on at least a portion of the polymer coating layer. In an embodiment, a method of forming a medical implant results in bioactive ceramic particles being partly embedded in the coating polymer layer.