PEEK-Ceramic Composite Orthopedic Implant with Coralline Structure
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Solution Overview
Problem
Current orthopedic implant materials often lack both load-bearing capacity and the ability to integrate with surrounding natural tissue, such as bone, which is essential for effective tissue repair and reconstruction in orthopedic surgery.
Innovation Solution
The development of orthopedic composites comprising a ceramic phase with a coralline structure derived from coral, combined with a non-resorbable polymer like PEEK, which provides both compressive strength and facilitates integration with natural bone through a porous structure that allows for bone ingrowth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ceramic materials with porous coralline structure are used, then tissue integration and bone ingrowth are facilitated, but load-bearing capacity is reduced
Solution Approach 1:
The patent combines ceramic particles (providing osteoconductivity and bone ingrowth) with polymer matrix (providing mechanical strength and load-bearing capacity) to create a composite material that simultaneously achieves both tissue integration and sufficient structural support
Solution Approach 2:
The invention uses composite materials consisting of ceramic particles dispersed in a polymer matrix, where the ceramic phase (hydroxyapatite, tricalcium phosphate, or coralline ceramic) provides biological activity and bone ingrowth capability, while the polymer phase provides mechanical strength and load-bearing properties
2Strength
If non-resorbable polymer is used, then load-bearing capacity is maintained, but integration with surrounding natural tissue is limited
Solution Approach 1:
The patent incorporates porous structures with controlled porosity (30-70%) and interconnected pore networks that allow bone ingrowth and tissue integration while maintaining sufficient mechanical strength through the polymer matrix and strategic pore distribution
Solution Approach 2:
The invention creates regions with different properties within the implant: surface regions with higher porosity for bone ingrowth and deeper regions with lower porosity for structural support, achieving both tissue integration and load-bearing capacity through spatial variation of material properties
3Adaptability or versatility
If resorbable ceramic composition is used, then integration with natural bone is improved, but compressive strength is insufficient
Solution Approach 1:
The patent modifies the physical and chemical parameters of the ceramic phase by controlling particle size (1-1000 micrometers), composition (hydroxyapatite, tricalcium phosphate, coralline ceramic), and distribution within the polymer matrix to optimize both bone integration and mechanical strength
Solution Approach 2:
The invention uses coralline ceramic that replicates the natural hierarchical structure of bone, providing osteoinductive properties and promoting bone ingrowth while maintaining structural integrity through the composite architecture
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
These composites offer a balance of load-bearing properties and tissue integration, maintaining compressive strength of 50-150 MPa while allowing for bone growth and integration, making them suitable for various orthopedic applications including spinal fusion and bone grafting.
Implementation Method 1
The infusing may involve placing the ceramic body into a mold and injecting the non-resorbable polymer into the mold so as to fill one or more of the channels
Data Source
Figure 1
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Figure 3a~3b
AI summary
Composites, constructs and implants comprising a non-resorbable polymer, such as polyetheretherketone (PEEK), having structure of interconnected struts, which may be coralline. Composites may comprise a first phase comprising a ceramic; and a second phase comprising a non-resorbable polymer; wherein each of the first and second phases have an interconnected strut structure and are substantially continuous through the composite. Implants may also comprise a non-porous component containing the non-resorbable polymer that is contiguous with a surface of the core, a surface of the porous layer (if present), or both. Methods are also provided comprising infusing a porous ceramic body, having a plurality of interconnected channels, with a non-resorbable polymer.