Polymeric Bone Defect Filler with Composite Porous Structure
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Solution Overview
Problem
Conventional bone replacement technologies face issues such as poor tensile, flexural, and shear properties, inadequate adhesion to surrounding bone, and lack of structural strength, leading to potential washout of fillers and limited bone ingrowth due to insufficient pore interconnectivity.
Innovation Solution
A bone defect filler composed of a particulate polymer and a polymeric binder, formed from a biocompatible polyurethane material, which provides improved pore interconnectivity, handling, and mechanical strength, allowing for better bone ingrowth and adhesion, with a kit including a prepolymer, polyol, and optional filler for mixing to create a porous structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional synthetic bone defect fillers are made resorbable and porous to allow bone remodeling, then bone remodeling is promoted, but tensile, flexural, and shear properties deteriorate and adhesion to surrounding bone worsens
Solution Approach 1:
The invention uses a composite material system consisting of polyurethane polymer particles dispersed in a curable adhesive composition. The polyurethane particles provide porosity and bone remodeling capability, while the curable adhesive matrix provides mechanical strength and adhesion. This composite structure resolves the contradiction by combining materials with complementary properties.
Solution Approach 2:
The invention changes the physical and chemical parameters of the bone defect filler by using a curable adhesive composition that transitions from a liquid state (for easy application and pore formation) to a cured state (for mechanical strength). The polyurethane particle size, distribution, and concentration are also optimized to balance porosity and mechanical properties.
2Strength
If polyurethane bone defect fillers are made liquid for in situ curing to improve tensile strength and adhesion, then mechanical strength and adhesive characteristics improve, but handling difficulty increases due to expansion and contamination risk
Solution Approach 1:
The polyurethane particles are pre-formed and dried before application, removing the harmful expansion effect to the bone defect site. The particles are prepared in advance with optimal porosity and size, so when mixed with the curable adhesive, they provide immediate structural support without expanding further, improving handling safety.
Solution Approach 2:
The polyurethane particles act as temporary, disposable structural elements that provide immediate framework and porosity during application, then serve their functional purpose throughout the healing process. Their pre-formed, stable nature eliminates handling risks while they fulfill their long-term bone regeneration support function.
3Stability of the object's composition
If polyurethane bone defect fillers are made porous to promote bone ingrowth, then bone ingrowth is promoted, but mechanical strength deteriorates
Solution Approach 1:
The composite structure combines polyurethane particles (providing porosity for bone ingrowth) with a curable adhesive matrix (providing mechanical strength). The adhesive binds the particles together, creating a unified structure where the porous particles enable bone regeneration while the continuous adhesive phase maintains overall mechanical integrity.
Solution Approach 2:
Different regions of the bone defect filler have different properties: the polyurethane particles provide localized porosity and osteoconductivity for bone ingrowth, while the curable adhesive matrix provides continuous mechanical support throughout the structure. This spatial differentiation of functions resolves the contradiction between porosity and strength.
4Adaptability or versatility
If particulate polymer bone defect fillers are used to conform to bone defect shape, then adaptability to defect geometry improves, but adhesive properties worsen leading to washout
Solution Approach 1:
The invention creates a composite where polyurethane particles (providing shape adaptability) are embedded in a curable adhesive matrix (providing adhesion). The adhesive binds the particles to each other and to the surrounding bone, preventing washout while maintaining the ability to conform to the defect geometry. The cured adhesive acts as a binding network that secures the particulate structure.
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 solution enhances bone ingrowth, reduces expansion and contamination susceptibility, and maintains sufficient mechanical strength for effective bone repair, offering improved handling and implantation characteristics compared to conventional methods.
Implementation Method 1
adhere the particulate polymer to surrounding bone
Implementation Method 2
porous structure for promoting new bone ingrowth
Data Source
AI summary
A bone defect filler for implantation in a bone defect of a patient includes a particulate polymer distributed within a polymeric binder. The particulate polymer includes a plurality of particles, which may have substantially the same material composition as the polymeric binder. The particles of the particulate polymer may be formed in a variety of shapes and/or sizes to provide the bone defect filler with improved pore interconnectivity, material expansion and contamination characteristics, while maintaining sufficient mechanical strength and handling characteristics for bone repair applications. The bone defect filler also provides the flexibility to be molded or shaped in situ to fill the bone defect.