US20140067082A1 - Bioresorbable ceramic composition for forming a three dimensional scaffold - Google Patents

Bioresorbable ceramic composition for forming a three dimensional scaffold Download PDF

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US20140067082A1
US20140067082A1 US13/832,455 US201313832455A US2014067082A1 US 20140067082 A1 US20140067082 A1 US 20140067082A1 US 201313832455 A US201313832455 A US 201313832455A US 2014067082 A1 US2014067082 A1 US 2014067082A1
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granules
coating
calcium
composition
scaffold
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Xinyin Liu
Mark Fulmer
Peter Schaut
Kevin Joye
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DePuy Synthes Products Inc
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DePuy Synthes Products Inc
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Assigned to SYNTHES USA PRODUCTS, LLC reassignment SYNTHES USA PRODUCTS, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FULMER, MARK, SCHAUT, Peter, JOYE, Kevin, LIU, XINYIN
Assigned to DePuy Synthes Products, LLC reassignment DePuy Synthes Products, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SYNTHES USA PRODUCTS, LLC
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Priority to US15/342,393 priority patent/US10357590B2/en
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L24/00—Surgical adhesives or cements; Adhesives for colostomy devices
    • A61L24/001—Use of materials characterised by their function or physical properties
    • A61L24/0042—Materials resorbable by the body
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L24/00—Surgical adhesives or cements; Adhesives for colostomy devices
    • A61L24/001—Use of materials characterised by their function or physical properties
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L24/00—Surgical adhesives or cements; Adhesives for colostomy devices
    • A61L24/02—Surgical adhesives or cements; Adhesives for colostomy devices containing inorganic materials
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/02—Inorganic materials
    • A61L27/10—Ceramics or glasses
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/02—Inorganic materials
    • A61L27/12—Phosphorus-containing materials, e.g. apatite
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/28—Materials for coating prostheses
    • A61L27/30—Inorganic materials
    • A61L27/32—Phosphorus-containing materials, e.g. apatite
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/50—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/50—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L27/56—Porous materials, e.g. foams or sponges
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/50—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L27/58—Materials at least partially resorbable by the body
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
    • B05D1/12—Applying particulate materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/007—After-treatment
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/34—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
    • C04B28/344—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders the phosphate binder being present in the starting composition solely as one or more phosphates
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2400/00—Materials characterised by their function or physical properties
    • A61L2400/06—Flowable or injectable implant compositions
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2420/00—Materials or methods for coatings medical devices
    • A61L2420/02—Methods for coating medical devices
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2420/00—Materials or methods for coatings medical devices
    • A61L2420/08—Coatings comprising two or more layers
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2430/00—Materials or treatment for tissue regeneration
    • A61L2430/02—Materials or treatment for tissue regeneration for reconstruction of bones; weight-bearing implants
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00836—Uses not provided for elsewhere in C04B2111/00 for medical or dental applications

Definitions

  • the present disclosure is directed towards a bioresorbable ceramic composition for forming a three dimensional scaffold for use in bone augmentation.
  • Synthetic ceramic compositions have been well known for use in bone repair and bone void filling procedures. Ceramic granules have been widely used for such procedures.
  • Ceramic granules such as calcium phosphate granules, is that once they are packed into placement in a bone void, an interconnected network of pores is created between the granules that allows for the penetration of fluids and new bone cells that can attach to the surfaces of the granules and begin remodeling and resorbing.
  • One drawback to the use of ceramic granules is migration issues associated with the non-cohesive nature of a granulated mixture.
  • Synthetic ceramic cements have also been widely used in bone repair and bone void filling procedures.
  • the ceramic cements are composed of calcium sulfate and/or calcium phosphate based powders that can be mixed into a paste and injected to set in situ, or alternatively can be pre-cast into a desired shape and then placed in vivo.
  • One advantage to using ceramic cements is that a relatively high volume of ceramic material can be placed into the bone void space. Additionally, the cement, once it has set, has a very low occurrence of migration from the implantation site.
  • One drawback to the use of ceramic cements is that there is little to no porosity at the time of implantation, preventing fluids and new bone cells from penetrating into the cement construct, and further that ceramic cement does not provide an optimum osteoconductive scaffold for bone remodeling.
  • US Pat. Appl. Publ. No. 2010/0249794 describes a cement system that contains calcium sulfate hemihydrate (CSH), monocalcium phosphate monohydrate (MCPM) powder, and ⁇ -tricalcium phosphate ( ⁇ -TCP) powder that forms an injectable bone graft substitute cement upon mixing with an aqueous solution.
  • CSH calcium sulfate hemihydrate
  • MCPM monocalcium phosphate monohydrate
  • ⁇ -TCP ⁇ -tricalcium phosphate
  • U.S. Pat. No. 7,754,246 describes a bulk mixture of ceramic cement and calcium phosphate granules which when mixed with an aqueous solution can set as a non-porous monolithic construct having the granules serve as a “reticulated framework.”
  • This mixture can either be preformed into a desired shape ex vivo and subsequently implanted, or mixed into a paste and injected/implanted such that the mixture can set in vivo. In either case, there is no porous network upon implantation until the calcium sulfate begins to resorb.
  • the present disclosure describes a bioresorbable ceramic composition that includes a plurality of biocompatible ceramic granules, each of the granules having a coating of a plurality of calcium containing particles, at least a portion of the particles being bound to at least a portion of an outer surface of each of the granules, where the bioresorbable ceramic composition is flowable in a dry state.
  • the calcium containing particles are calcium sulfate particles, in another embodiment they are calcium phosphate particles, and in certain embodiments the particles can be a blend or combination of both.
  • the biocompatible ceramic granules of the present disclosure can include calcium phosphate granules, calcium sulfate granules, bioglass granules and other silicate-based biocompatible ceramic granules, as well as blends and mixtures thereof.
  • the particles, granules, or both can further include additional elements such as silicon, magnesium, strontium, zinc, and mixtures and derivatives thereof, which can be combined with the granules, particles, or both, either through chemical substitution or the addition or incorporation of metal oxides or salts containing the elements, or both.
  • the coating of the present disclosure can include, in one embodiment, a single coating, or alternatively can include multiple coatings, for example, at least two coatings, and in certain embodiments, three or more coatings, for example up to about five coatings.
  • the present disclosure also describes a method of manufacturing the biocompatible ceramic composition that includes the steps of:
  • the process of dehydrating is a partial dehydration.
  • the step of dehydrating is a lyophilizing step.
  • the dehydrating step is a multi-step process including autoclaving and lyophilizing.
  • the step of dehydrating can control the degree of reactivity of the coating such that at least a portion of the coating is reactive to subsequent hydraulic cement reactions.
  • the portion of the coating that is reactive is ⁇ -tricalcium phosphate ( ⁇ -TCP).
  • the portion of the coating that is reactive is calcium sulfate hemihydrate.
  • the particles are introduced into the mixing step in the hemihydrate form as calcium sulfate hemihydrate (CSH).
  • CSH calcium sulfate hemihydrate
  • the hemihydrate will react to form the dihydrate as calcium sulfate dihydrate (CSD) such that the resultant coating will primarily contain CSD.
  • CSD calcium sulfate dihydrate
  • conversion from CSD back to reactive CSH can occur with the removal of water.
  • This conversion can be controlled as desired through the dehydration step to enable at least a portion of the coating to have a desired level of CSH conversion. This can allow the coating to have a reactive property, in the form of CSH, for subsequent hydraulic cementitious reactions.
  • certain calcium phosphate compositions can be included that will react in a multi-step reactive process that results in a cured final stable apatite composition forming the coating.
  • the dehydration can be controlled where at least a portion of the calcium phosphate composition does not fully cure to a stable apatite composition such that the calcium phosphate composition is reactive to subsequent hydraulic reactions.
  • at least a portion of the coating that is reactive is ⁇ -TCP.
  • the present disclosure additionally describes a three-dimensional bioresorbable ceramic scaffold for repairing a bone defect
  • the scaffold is formed from a plurality of biocompatible ceramic granules, each of the granules having a coating of a plurality of calcium containing particles, at least a portion of the particles being bound to at least a portion of an outer surface of each of the granules, where the plurality of granules defines a three-dimensional scaffold at a locus of implantation, and where, at the time of implantation at the locus, the scaffold defines an interconnected pore network between outer walls of adjacent granules.
  • the scaffold can further include a binding agent that maintains the plurality of granules adjacently to one another within the locus of implantation.
  • the binding agent can be a cementitious powder, and according to another embodiment the binding agent can be a gel or hydrogel.
  • the scaffold can additionally include an active agent, for example, an agent that facilitates or promotes new bone growth, such as an osteoinductive or osteogenic composition.
  • the scaffold can further include a delivery fluid that maintains the scaffold in a flowable consistency suitable for injection and/or manual shaping or manipulation.
  • the delivery fluid is a non-aqueous medium.
  • the present disclosure further describes a method of forming a three dimensional bioresorbable ceramic scaffold for bone repair that includes the steps of:
  • the scaffold is implanted to the locus prior to the contacting of the binding agent.
  • the scaffold is contacted with the binding agent prior to the step of implanting.
  • the method can further include contacting with an active agent.
  • the step of implanting can, according to one embodiment, include injecting the biocompatible ceramic composition to a locus, where the biocompatible ceramic composition includes a delivery fluid.
  • the step of implanting can include manually implanting the biocompatible ceramic composition, where the biocompatible ceramic composition includes a delivery fluid.
  • the resultant scaffold is osteoconductive and has a network of interconnected pores defined by the walls of the coated granules, which provide channels for bone cells to penetrate throughout at the time of implantation, and that encourage bony ingrowth.
  • FIG. 1 is a graphical representation of the measured indentation force for coated granules of the present disclosure mixed with CaP powder mixture versus uncoated granules.
  • the present disclosure is directed towards a biocompatible, resorbable, ceramic composition including a plurality of biocompatible ceramic granules, where each of the granules has a coating including a plurality of calcium containing particles, and at least a portion of the particles are bound to at least a portion of an outer surface of each of the granules.
  • the biocompatible ceramic composition according to the present disclosure is flowable in a dry state.
  • the ceramic granule can be formed from any ceramic composition suitable for implantation into a human body.
  • Such ceramic compositions are well known and can include, for example, ⁇ -calcium sulfate, ⁇ -calcium sulfate, calcium phosphates (e.g., beta-tricalcium phosphate ( ⁇ -TCP), apatites (such as hydroxyapatite or carbonated apatite), brushite, or octacalcium phosphate, or a mixture and combination thereof), and bioglass compositions.
  • the granule is of a calcium phosphate composition
  • the chemical formulation of the calcium phosphate composition can be formulated or altered as desired.
  • the calcium phosphate composition is ⁇ -TCP, preferably phase pure ⁇ -TCP.
  • the resorption in vivo of ⁇ -TCP closely matches the rate of new bone growth or remodeling.
  • the calcium phosphate composition is hydroxyapatite (or a derivative or substituted version thereof). Hydroxyapatite closely matches the natural mineral composition of bone.
  • the calcium phosphate composition can be a mixture or blend of both ⁇ -TCP and hydroxyapatite.
  • the biocompatible ceramic granules according to the present disclosure can have physical features and morphology suitable for the use as a bone void filler.
  • the granules can have an average size diameter in the range of 0.1 mm to 6.0 mm, preferably in the range of 0.1 mm to 3 mm, and more preferably in the range of 0.125 mm to 2 mm.
  • the granules can have a substantially irregular shape, as well as a substantially regular three-dimensional geometry, such as a generally sphere, rod, wedge, or prismatic shape.
  • the pores can be substantially interconnected, or alternatively substantially non-interconnected.
  • the average pore size diameter for porous granules can be in the range of about 10 um to 500 um; preferably in the range of about 100 um to about 500 um.
  • the pores can have one or more discreet average pore size ranges, for example a granule that exhibits discreet micro and macro pore sizes in same granule, known as bimodal distribution.
  • the granules can have an average pore volume or porosity (measured as percentage of the total granule volume) in the range of 30% to about 80%, preferably in the range of about 40% to about 80%, and more preferably in the range of about 50% to about 70%.
  • the coating is formed from calcium containing particles; in a preferred embodiment the particles are either 1) a calcium sulfate composition; or 2) a calcium phosphate (CaP) composition.
  • the coating can include a blend or mixture of more than one type of calcium containing particle (e.g., a mixture of calcium sulfate and CaP particles, or a mixture of CaP particles and calcium carbonate particles).
  • the calcium sulfate compositions suitable for forming the calcium containing particles are preferably calcium sulfate hemihydrate (CSH) and calcium sulfate dehydrate (CSD).
  • CSH calcium sulfate hemihydrate
  • CSD calcium sulfate dehydrate
  • the calcium sulfate particles have an average size of about 20 um, and can be anywhere in the range of about 10 um to about 40 um.
  • CSH is a composition that in the presence of an aqueous medium cementitiously reacts to form CSD:
  • Calcium sulfate has a relatively high dissolution constant as compared to other calcium containing ceramic compositions as shown in Table 1 below.
  • the dissolution profile of calcium sulfate in vivo is generally in the range of 4 weeks to about 8 weeks depending on the volume and the location of the material being implanted in vivo.
  • the relatively rapid release of Ca + ions at the locus of implantation can be beneficial in aiding new bone formation.
  • CSH present in the coating can cure (or set) in vivo to form CSD and thus form a cement framework among a plurality of the coated granules that are adjacent to one another.
  • the coating is formed of substantially CSH particles.
  • the coating is formed of substantially CSD particles.
  • the coating is formed substantially of a blend of CSD and CSH particles.
  • the ceramic granule is a calcium phosphate granule, for example an apatite or ⁇ -TCP granule.
  • the calcium sulfate particles are able to bind to at least a portion of the outer surface of the biocompatible ceramic granule through an interlocking network of crystals between the crystalline structure of the calcium sulfate particles and the crystalline structure of the ceramic granules. This interlocking of crystals can result from different aspects of the coating process.
  • one possible way that crystal interlocking can occur is that the presence of calcium sulfate (either in hemihydrate or dihydrate form) at the surface of the biocompatible ceramic granule in the presence of an aqueous medium causes some level of solubility of the granule at the surface, resulting in a degree of penetration of the calcium sulfate into the surface region of the granule.
  • the surface of the granule re-precipitates (re-crystallizes) among and through the crystal structure of the calcium sulfate resulting in the coating being bound to the surface of the granule.
  • the crystal interlocking can occur is where the calcium sulfate (either in hemihydrate or dihydrate form) is present in an aqueous medium at the surface of the biocompatible ceramic granule that is not fully cured (typically a CaP granule; most typically an apatite granule).
  • the calcium sulfate can penetrate into the surface region of the partially cured granule.
  • the surface of the granule will crystallize among and through the calcium sulfate crystal network resulting in the coating being bound to the surface of the granule.
  • the CaP compositions suitable for forming the calcium containing particles are preferably: ⁇ -tricalcium phosphate ( ⁇ -TCP) Ca 3 (PO 4 ) 2 ; ⁇ -tricalcium phosphate ( ⁇ -TCP) Ca 3 (PO 4 ) 2 ; mono-calcium phosphate monohydrate (MCPM) Ca(H 2 PO 4 ) 2 .H 2 O; mono-calcium phosphate anhydrous (MCPA) Ca(H 2 PO 4 ) 2 ; dicalcium phosphate dihydrate (DCPD, brushite) CaHPO 4 .2H 2 O; dicalcium phosphate anhydrous (DPCA, monetite) CaHPO 4 ; tetracalcium phosphate (TTCP) Ca 4 (PO 4 ) 2 O; and octacalcium phosphate (OCP) Ca 8 H 2 (PO 4 ) 6 .5H 2 O.
  • calcium carbonate (calcite) CaCO 3 can be included with the CaP compositions described herein
  • the calcium containing particles of the present disclosure when including a CaP composition can bond onto a portion of an outer surface of the biocompatible ceramic granules through chemical bonds.
  • a CaP composition when including a CaP composition can bond onto a portion of an outer surface of the biocompatible ceramic granules through chemical bonds.
  • the individual chemical compounds present i.e. the calcium, phosphate, carbonate and/or sulfate ions are released from both the surface of the granules and the particles during the coating process, and therefore participate in a chemical reaction with one another at the surface of the granules.
  • the newly formed brushite from Eq. 3 could react with additional TCP based on Eq. 2a to form apatite.
  • the release of the carbonate ions can result in substitution of carbonate in any final apatite structure.
  • other additional elements can be incorporated into the biocompatible ceramic composition of the present disclosure.
  • the previously described embodiment including the addition of calcite to the CaP composition adds the additional carbonate ions to the ceramic compositions.
  • Other suitable elements can include, for example, silicon, magnesium, strontium and zinc.
  • the elements can be incorporated through direct substitution into the chemical formula of the chemical compositions of the calcium containing particles or the biocompatible ceramic granules.
  • the element can be incorporated through the addition of certain oxide powders or salts containing one or more of the desired element.
  • the addition of the oxide powders or salts can be accomplished in such a manner that the element is distributed evenly throughout the body of the granule.
  • the addition of the element can be localized within one or more regions of the granule, for example along or within a surface of the granule, or localized within a core region.
  • the additional element can be incorporated into the aqueous medium used to form the coating, for example either dissolved or suspended in the aqueous medium.
  • any of the above-described embodiments regarding the incorporation of certain elements to the calcium containing particles or the biocompatible ceramic granules, either through substitution or addition, can be combined or modified as desired, such that the resultant particles and/or granules could include both substituted elements as well as elements incorporated by addition.
  • the coating of calcium containing particles is at least partially bound to at least a portion of the outer surface of the biocompatible ceramic granules.
  • the coated granules can have a weight ratio range between the weight of the granules and the particles of about 80:20 to about 40:60; preferably about 75:25 to about 45:65, and more preferably about 70:30 to about 50:50.
  • the weight ratio range is about 95:5 to about 30:70, preferably about 90:10 to 40:60, and more preferably about 85:15 to 50:50. It should be appreciated that the weight ratio ranges previously described are directed to the weight percentage distribution of the coated granules of the biocompatible ceramic composition.
  • a three-dimensional scaffold can be formed from the biocompatible ceramic composition of the present disclosure that may further include or be combined with additional components (for example, cementitious powders), where the resultant scaffold would have a different weight ratio than the coated granule disclosed above.
  • additional components for example, cementitious powders
  • the biocompatible ceramic composition is flowable in a dry state. Dry powder and granular compositions or mixtures that can be poured readily through a small funnel are considered to be flowable.
  • the flowability rate of certain compositions can provide a measurement and index for the performance of a variety of dry powders and granules.
  • Flowability (which can also be referred to as pourability) is a measure of the time required for a standard quantity of dry material to flow through a funnel of specified dimensions and can be measured under ASTM standards (as discussed in further detail below).
  • the present disclosure further describes a method of producing the biocompatible ceramic composition including:
  • any number of granulation or coating process and devices which are well known in the art could be used to manufacture the coated granules according to the present disclosure such as a high shear granulator, fluid bed granulator, drum granulator, and/or pan/disc coaters. It should be appreciated that the precise sequence of steps can be modified according to the type of equipment and/or process that is used to produce the coated granules that comprise the biocompatible ceramic composition. Typically, the granules, the particles, and the aqueous medium are all present at the same location and at the same point in time.
  • the dry biocompatible ceramic granules and dry calcium containing particles may be premixed after which the aqueous medium is introduced through the use of a sprayer.
  • dry biocompatible ceramic granules may be pre-soaked in an aqueous medium and then the calcium containing particles would be introduced.
  • the granules and calcium sulfate particles are kept in some state of agitation during the coating process to attempt to ensure an even distribution of the particles onto the outer surfaces of the granules.
  • the coating process can be performed more than once, if so desired, for example, to ensure that each coated granule has an appropriate amount of calcium containing particles, and/or various additional elements, and/or active agents contained thereon in different coating layers.
  • the process can further comprise forming at an additional coating on the coated granules.
  • the coated granules include a single coating.
  • the coated granules include an additional/multiple coating, for example, at least two coatings, and in certain embodiments, three or more coatings, for example up to about five coatings.
  • an outermost coating includes calcium sulfate.
  • the coating process can be conducted in a high shear granulator, e.g. TMG manufactured by Glatt Air Techniques, Inc. (Ramsey, N.J.).
  • the high shear granulator has an agitator on the bottom of the mixing vessel that can be set at various agitation speeds to control the coating process. It also has a side chopper which can further facilitate the coating process.
  • the aqueous medium e.g. water
  • the step of dehydrating serves to remove a desired amount of excess moisture remaining after completion of the coating process.
  • the step of dehydrating can be a partial dehydration, for example, to remove excess water that is not chemically bound to the coating and/or granule.
  • the step of dehydrating can also be used to convert the chemical composition and structure of the coating and/or granule by removal of chemically bound water, for example conversion of a dihydrate moiety to its hemihydrate state, or accelerating the formation of a stable inert apatite structure.
  • the degree of dehydration can be controlled and varied as desired. According to one embodiment, the dehydration can be controlled where at least a portion of the coating after the dehydrating step is reactive to subsequent hydraulic reactions.
  • dehydration is done through lyophilization (i.e., freeze drying).
  • dehydration is done through the use of an autoclave (as described below).
  • the use of an autoclave generally, in the process of dehydration, is to provide a controlled level of heat, pressure, and moisture in the atmosphere during dehydration such that by raising heat and/or pressure water can be removed from the coated granules without causing the removal of water that is desired to remain.
  • the dehydration process is done using an oven, for example a vacuum oven.
  • the step of dehydrating can be a passive step, for example, allowing the coated granules to be exposed to the environment and permitting natural evaporation to occur, such as leaving the granules on a surface overnight, or for a number of days to dry.
  • the particles are introduced into the mixing step in the hemihydrate form as calcium sulfate hemihydrate (CSH).
  • CSH calcium sulfate hemihydrate
  • the hemihydrate form will cementitiously react to form the dihydrate form as calcium sulfate dihydrate (CSD) such that the resultant coating will primarily contain CSD.
  • CSD calcium sulfate dihydrate
  • conversion from CSD back to reactive CSH can occur with the removal of water. This conversion can be controlled as desired through the dehydration step to enable a desired level of CSH conversion to occur.
  • CSD can be converted back to reactive CSH through the use of an autoclave to dehydrate the composition.
  • Typical autoclave conditions suitable for converting CSD to CSH are temperatures exceeding 100° C. and water vapor pressures that exceed atmospheric pressure.
  • the step of dehydrating and converting at least a portion of the CSD to CSH involves autoclaving the CSD at 121° C. or 135° C. and 15 psi for about 15 minutes up to 60 minutes.
  • the calcium containing particles are calcium phosphate particles
  • an exemplary reaction mechanism in an aqueous medium has been described above.
  • the exemplary CaP reaction mechanism can ultimately lead to a stable apatite structure (Eq. 1 to Eq. 2a) if fully cured.
  • the dehydrating step can, according to one embodiment, prevent the reaction from proceeding to a final stable apatite by removing the water necessary for the reaction to proceed.
  • at least a portion of the coating is bound to at least a portion of the outer surface of the granule after the dehydrating step, at least a portion of the coating is reactive to subsequent hydraulic cementitious reactions in the form of ⁇ -TCP.
  • a three-dimensional bioresorbable ceramic scaffold for augmenting or repairing a bone defect is described that is formed from the coated granules of the biocompatible ceramic composition previously described.
  • the plurality of granules defines a three-dimensional scaffold at a locus of implantation, and at the time of implantation at the locus, the scaffold defines an interconnected pore network between outer walls of adjacent granules.
  • the scaffold is bioresorbable and the interconnected pore network allows for the penetration of fluids and cells into the scaffold.
  • the interconnected pore network also provides an osteoconductive environment for new bone cells to attach and remodel utilizing the materials of the resorbable scaffold.
  • the interconnected pore network can have a volume, according to one embodiment, of about 20% to about 90% of the total scaffold volume, preferably about 30% to about 80%, more preferably 35% to about 70%, and most preferably about 40% to about 60%.
  • the average pore diameter of the interconnected pore network can be in the range of about 10 um to about 1000 um, more preferably 100 um to about 500 um.
  • the coated granules of the scaffold can be cementitiously bound to one another.
  • Such embodiments can be formed from the process described previously utilizing the dehydrating step, where the dehydrating step can be controlled where at least a portion of the coating is reactive to subsequent hydraulic reactions.
  • the reactive portion of the coating includes CSH.
  • the reactive portion of the coating includes ⁇ -TCP.
  • aqueous medium examples include water, saline, blood, bone marrow aspirate, and aqueous medium containing bioactive agents, as well as biocompatible buffered solutions such as, for example, phosphate buffered saline (PBS).
  • PBS phosphate buffered saline
  • the scaffold can further be combined with or include an accelerant composition that can facilitate the setting of the adjacent coated granules to one another.
  • the accelerant compositions can include for example, calcium sulfate dihydrate, potassium sulfate, zinc sulfate and sodium sulfate.
  • the scaffold can further include a binding agent that is capable of reducing or hindering migration of the coated granules of the scaffold.
  • the binding agent can be any biocompatible material that can maintain the plurality of granules adjacently to one another within the locus of implantation.
  • the binding agent does not inhibit the flow of fluids and cells through the interconnected pore network.
  • the binding agent is a cementitious powder.
  • Biocompatible cementitious powders are well known in the art and can include for example crystalline calcium phosphates or calcium sulfates; dicalcium phosphate anhydrous-CaHPO 4 ; dicalcium phosphate dihydrate-CaHPO 4 .2H 2 O; ⁇ -tricalcium phosphate-Ca 3 (PO 4 ) 2 ; ⁇ ′-tricalcium phosphate-Ca 3 (PO 4 ) 2 ; ⁇ -tricalcium phosphate-Ca 3 (PO 4 ) 2 ; hydroxyapatite-Ca s (PO 4 ) 3 OH, or Ca 10 (PO 4 ) 6 (OH) 2 ; tetracalcium phosphate-Ca 4 (PO 4 ) 2 O; octacalcium phosphate-Ca 8 H 2 (PO 4 ) 6 .5H 2 O; calcium sulfate anhydrous-CaSO 4 ; ⁇ -
  • the cementitious powder can be combined with the scaffold perioperatively, or alternatively can be pre-packaged with the coated granules that form the scaffold.
  • the cementitious powder can be present in amounts that range from about 10% to about 50% by weight of the scaffold. Preferably, the cementitious powder is present in an amount of about 20% to about 30% by weight of the scaffold.
  • the binding agent is a polymer based composition, such as a hydrophilic polymer.
  • a polymer based composition such as a hydrophilic polymer.
  • Such compositions can be naturally or synthetically derived and can include gels, hydrogels, cross-linking polymers, or blends and mixtures thereof.
  • Aqueous polymers that form gels or hydrogels are well known in the art and can include for example polyvinyl pyrrolidone, polyvinyl alcohol, polyethylene glycol, and poloxamers (which are copolymers of polyoxyethylene and polyoxypropylene).
  • the binding agent can include polyalkylene oxide based compositions, for example functionalized polyalkylene oxides.
  • One example of a preferred functionalized polyalkylene oxide is multifunctional cross-linking polyalkylene oxides.
  • the binding agent is a protein or polysaccharide based gel or hydrogel. Proteins that form gels or hydrogels are well known in the art and can include for example, collagen, elastin, fibrin, albumin and silk proteins.
  • Polysaccharides that form gels or hydrogels are well known in the art and can include for example alginate, chitosan, hyaluronate, heparan, dextran, dextrin, polydextrose, cellulose derived polymers (such as carboxymethyl cellulose, hydroxypropylmethyl cellulose, hydroxypropyl cellulose, etc.).
  • Alginate based hydrogel is a particularly preferred hydrogel.
  • Alginate occurs naturally in seaweed mainly in its calcium, magnesium and sodium salt form. It is a block copolymer composed of longer homopolymeric regions of mannuronate and guluronate, interspersed with regions of alternating mannuronate/guluronate structure. Typically, the guluronate regions provide the gel forming capability of alginate while the mannuronate and mannuronate/guluronate regions provide flexibility to the polymer chains. Alginate's gel forming capability is a function of the guluronate monomer regions in the polymer chains.
  • One guluronate region on the alginate chain can be crosslinked to another similar region on another chain via a multivalent ion such as magnesium or calcium for example.
  • the cation provides a junction zone for the polymer chains resulting in a gelation of the alginate.
  • alginate is particularly preferred where the coating includes calcium sulfate because the calcium ions present in the calcium sulfate particles of the coated granules can provide a source of calcium ions at a relatively rapid rate for crosslinking the alginate as described above.
  • Alginate content in aqueous solutions suitable for use as a binding agent can be in the range of about 0.1% to about 5%, with about 0.5% to about 2% preferred.
  • the scaffold can be combined with an active agent or agents that can facilitate the growth of new bone, or provide other therapeutic benefits such as for example, reduced inflammatory response, anti-microbial treatment, anti-cancer treatment, or pain relief.
  • Active agents suitable for facilitating new bone growth can be osteogenic, osteoinductive, or both.
  • Some examples of active agents suitable for facilitating new bone growth include autograft, bone marrow aspirate, mesenchymal stem cells, progenitor cells, pre-osteoblasts, and proteins or peptides that are related to bone formation, healing, and repair.
  • proteins include bone morphogenic proteins (BMPs), osteogenic proteins (OP), transforming growth factors (TGF), insulin-like growth factor (IGF), platelet-derived growth factor (PDGF), vascular endothelial growth factor (VEGF), and certain osteoinductive small molecules such as those disclosed in U.S. patent application Ser. No. 13/404,097, which is hereby incorporated by reference in its entirety.
  • Certain preferred bone morphogenic proteins include BMP-2 and BMP-7.
  • Active agents suitable for providing additional types of therapeutic benefits can include for example antibiotics, analgesics, and cancer treatment drugs.
  • the active agents listed herein can be combined with one another in any suitable combination as desired.
  • a method of a forming a three dimensional bioresorbable ceramic scaffold for bone repair includes:
  • the method can further include the optional step of contacting with an active agent.
  • the coated granules of the bioresorbable ceramic composition can be implanted to a locus (e.g., a bone void) and then subsequently contacted at the locus with a binding agent.
  • the step of implanting includes injecting to the locus, and in an alternative embodiment, the step of implanting includes manually applying to the locus.
  • the contacting may also include contacting with an aqueous medium.
  • the coated granules, the binding agent, and optionally, the aqueous medium can be combined prior to the step of implantation.
  • the individual components are combined into a slurry or other colloidal type mixture and then implanted via a syringe or other type of injection device, or alternative manually placed into the locus.
  • the binding agent can, in some embodiments, also serve as the aqueous medium, for example, where the binding agent is an aqueous solution having about 1% alginate content.
  • the step of contacting an active agent can occur at other points in the process.
  • the active agent can be contacted with the scaffold after implantation.
  • the active agent can be contacted with the composition prior to the step of forming the scaffold.
  • the active agent can be combined with the aforementioned components prior to implantation as previously described.
  • the active agent can be included either as a standalone component, as well as combined with any of the other components prior to contact.
  • the active agent could be dissolved within the aqueous medium prior to contact with either the scaffold or the other components.
  • the contact or combination of the individual elements that may be used to form the scaffold i.e., the bioresorbable ceramic composition, the binding agent, and/or either the aqueous medium, and/or the active agent
  • the contact or combination of the individual elements that may be used to form the scaffold i.e., the bioresorbable ceramic composition, the binding agent, and/or either the aqueous medium, and/or the active agent
  • the contact or combination of the individual elements that may be used to form the scaffold i.e., the bioresorbable ceramic composition, the binding agent, and/or either the aqueous medium, and/or the active agent
  • the contact or combination of the individual elements that may be used to form the scaffold can be undertaken in any possible permutation or sequence, both at the locus, as well as prior
  • the biocompatible ceramic composition can be stored and/or delivered to the locus of implantation in a suitable delivery fluid.
  • the delivery fluid can, according to one embodiment, maintain the composition in a storage stable state until implantation.
  • the delivery fluid can also maintain the composition in a flowable consistency that is suitable for injection and/or manual shaping or manipulation (e.g., a putty).
  • the step of implanting can also include injecting the biocompatible ceramic composition to the locus, where the biocompatible ceramic composition includes a delivery fluid.
  • the step of implanting can include manually implanting the biocompatible ceramic composition, where the biocompatible ceramic composition includes a delivery fluid.
  • the delivery fluid can enable the granulated ceramic composition to approach a putty-like consistency, which permits a manual shaping of the ceramic composition to a shape approximating the locus of implantation.
  • the delivery fluid is a non-aqueous biocompatible medium to prevent any hydraulic reaction from occurring prior to implantation.
  • Suitable candidates include glycerol (i.e. glycerin), n-methyl-2-pyrrolidone (NMP), 2-pyrrolidone, low molecular weight polyethylene glycols (such as PEG 400), and low molecular weight poloxamers (such as poloxamer 124), or combinations of such.
  • water-insoluble organic liquids that are well known in the art that can be utilized as suitable delivery fluids.
  • a non-restrictive list of exemplary organic liquids includes: glycerine triacetate, glycerine tributyrate, glycerine trioleate, glycerine dioleate, glycerine monooleate, caprylocaprate, decyloleate, isopropyl myristate, isopropyl palmitate, oleic acid, oleyl alcohol, oleyl oleate, short-chain triglycerides, medium-chain triglycerides, short-chain and medium-chain fatty acid esters of propylene glycol, ethylbenzoyl acetate, ethylbutyrate, ethylbutyryl acetate, ethyl oleate, ethyl caproate, ethyl caprylate, ethyl caprate, ethyl laurate, ethyl laevulinate, ethyl my
  • CSH calcium sulfate hemihydrate
  • chronOS granules ⁇ -TCP, 0.5-0.7 mm
  • TMG high shear granulator Glatt Air Techniques, Ramsey, N.J.
  • 25 g of water was delivered into the mixing vessel at a rate of 8 g/min.
  • the agitator was set to 150 rpm, and the chopper was set to 300 rpm.
  • the coating process had a duration of 10 minutes. In this coating process, CSH reacted with the water and converted to calcium sulfate dihydrate (CSD).
  • the coated granules were transferred to an autoclave safe bottle and autoclaved at 135° C. and 15 psi for 10 minutes.
  • the autoclave step converted a portion of the CSD to CSH.
  • the granules were then lyophilized to remove excess moisture remaining from the autoclave step.
  • the resultant coated granules (Lot#001-2) were analyzed for XRD, BET, micro-CT and SEM.
  • 125 g of calcium sulfate hemihydrate (CSH) (JT Baker) and 125 g of chronOS granules ( ⁇ -TCP, 0.5-0.7 mm) (Lot#2162065, Synthes USA, LLC) were premixed in TMG high shear granulator (Glatt Air Techniques, Ramsey, N.J.) with a one liter mixing vessel. 38 g of water was delivered into the mixing vessel at a rate of 8 g/min. The agitator was set to 150 rpm, and the chopper was set to 300 rpm. The coating process had a duration of 10 minutes.
  • CSH reacted with the water and converted to calcium sulfate dihydrate (CSD).
  • CSD calcium sulfate dihydrate
  • the coated granules were transferred to an autoclave safe bottle and autoclaved at 135° C. and 15 psi for 10 minutes.
  • the autoclave step converted a portion of the CSD to CSH.
  • the granules were then lyophilized to remove excess moisture remaining from the autoclave step.
  • the resultant coated granules (Lot#002) were analyzed for XRD, BET, micro-CT and SEM.
  • CSH calcium sulfate hemihydrate
  • chronOS granules ⁇ -TCP, 1.4-2.8 mm
  • TMG high shear granulator Glatt Air Techniques, Ramsey, N.J.
  • the agitator was set to 150 rpm, and the chopper was set to 300 rpm.
  • the coating process had a duration of 10 minutes.
  • CSH reacted with the water and converted to calcium sulfate dihydrate (CSD).
  • CSD calcium sulfate dihydrate
  • the coated granules were transferred to an autoclave safe bottle and autoclaved at 135° C. and 15 psi for 10 minutes.
  • the autoclave step converted a portion of the CSD to CSH.
  • the granules were then lyophilized to remove excess moisture remaining from the autoclave step.
  • the resultant coated granules (Lot#005) were analyzed for XRD, BET, and SEM.
  • CSH calcium sulfate hemihydrate
  • apatite granules Lit #HA-522, Synthes USA, LLC
  • TMG high shear granulator Glatt Air Techniques, Ramsey, N.J.
  • 24 g of water was delivered into the mixing vessel at a rate of 8 g/min.
  • the agitator was set to 150 rpm, and the chopper was set to 300 rpm.
  • the coating process had a duration of 12 minutes. In this coating process, CSH reacted with the water and converted to calcium sulfate dihydrate (CSD).
  • the coated granules were transferred to an autoclave safe bottle and autoclaved at 135° C. and 15 psi for 10 minutes.
  • the autoclave step converted a portion of the CSD to CSH.
  • the granules were then lyophilized to remove excess moisture remaining from the autoclave step.
  • the resultant coated granules (Lot#008-XL-8) were analyzed for XRD, BET, and SEM.
  • TMG high shear granulator Gaatt Air Techniques, Ramsey, N.J.
  • the purpose of this test was to evaluate the dry flow rate of the coated granules of Examples 1, 2 and 5 against uncoated chronOS granules by themselves in addition to the uncoated granules with the calcium particles used in the respective coatings (i.e., calcium sulfate particles for Examples 1 and 2, and the ⁇ -TCP, calcite, MCPM mixture for Example 5).
  • the test was conducted using a modified pourability test per ASTM D195-96 (2010) standard test methods for apparent density, bulk factor, and pourability of plastic materials.
  • Kimax 58 glass funnel opening at the bottom: 4.90 mm (ID); opening at the top: 88.00 mm (ID).
  • Kimax 58 glass funnel opening at the bottom: 4.90 mm (ID); opening at the top: 88.00 mm (ID).
  • the glass funnel was mounted on the lab stand. For every sample, ⁇ 50 g was weighed out (the actual mass was recorded for each sample), and poured into the funnel with the bottom opening closed. The digital timer was started at the same time the funnel bottom opening was opened. The sample was allowed to run freely from the funnel and the timer was stopped at the instant the last of the sample left the funnel. The final volume of the sample was recorded from reading the graduated cylinder, and the mass of the sample that went through the funnel was also recorded.
  • CSH Calcium sulfate hemihydrate powder
  • JT Baker JT Baker
  • P/N#1463-07 2.
  • chronOS granules 0.5-0.7 mm (Lot#2162065, Synthes USA, LLC)
  • the coated granules had an increased dry flow rate relative to the uncoated chronOS, and also had greater dry flow rate than the CSH:chronOS mixtures. Using one-way ANOVA (95% confidence interval) with Tukey post hoc analysis (Minitab 15), it was found that the dry flow rates of both of the coated granule samples were significantly different from the uncoated chronOS as well as all CSH:chronOS mixture samples tested in this study. The coated granules had a higher dry flow rate as compared to both the uncoated chronOS granules as well as the mixtures of calcium sulfate powder and chronOS granules.
  • test method in this study was modified from ASTM D1895-96 (2010), which is for powdered and or granulated plastic materials.
  • the fundamental theory of pourability i.e. a measure of the time required for a standard quantity of material to flow through a funnel of specified dimensions, also works for ceramic granules and powders. Therefore, a similar test setup was used to evaluate the dry flow rate of the samples.
  • the funnel dimensions used in this study were different from the ASTM standard. However, all samples evaluated in this study were tested using the same experimental setup, including the funnels. Therefore, the dry flow rates of the different samples that were tested indicate measurable differences of the flow behaviors of different samples.
  • chronOS granules, 0.5-0.7 mm LiquinOS granules, 0.5-0.7 mm (Lot#1010030, Synthes USA, LLC) 2. Calcium phosphate (CaP) powder mixture composed of:
  • the coated granules had an increased dry flow rate relative to the uncoated chronOS, and also had greater dry flow rate than the CaP Powder:chronOS mixtures.
  • Using one-way ANOVA (95% confidence interval) with Tukey post hoc analysis (Minitab 15), it was found that the dry flow rates of both of the coated granule samples were significantly higher than the uncoated chronOS as well as both CaP Powder:chronOS mixture samples (p-value 0.000). No differences of dry flow rate were found for the two coated granule groups.
  • Example 5 The two lots of granules obtained in Example 5 were mixed with CaP powder mixture of ⁇ -TCP (Synthes 40-0014, Lot#2000422), calcite (Synthes 10-0074, Lot#0405004) and MCPM (Synthes 40-0012, Lot#1999925) at a mass ratio of 60:40.
  • chronOS granules (0.5-0.7 mm, Lot#1010030, Synthes) were used as control, which also mixed with the same calcium phosphate powder mixture. 3.87 wt % dibasic sodium phosphate heptahydrate aqueous solution was used as the hydration fluid for all groups.
  • the samples were placed into indentation sample holders, and then placed into phosphate buffered saline (PBS, pH7.4) at 37° C.
  • PBS phosphate buffered saline
  • the indentation force was measured using a modified Gilmore needle method on a mechanical tester (MTS, Eden Prairie, Minn.) to evaluate the setting behaviors.
  • the peak load indicates the resistance of the sample to the indentor, and thus serves as a measure for the setting behaviors of the samples.
  • the agitator was set to 150 rpm, and the chopper was set to 300 rpm.
  • the coating process had a duration of 10 minutes.
  • the powder mixture and the surface of f3-TCP granules reacted with water, resulting in calcium phosphate coating on the ⁇ -TCP granules.
  • the coated granules were lyophilized (Lot#N03-1) and SEM images of the granule were taken.
  • the agitator was set to 150 rpm, and the chopper was set to 300 rpm.
  • the coating process had a duration of 10 minutes. In this coating process, the powder mixture and the surface coated granules reacted with water, resulting in an additional calcium phosphate coating on the ⁇ -TCP granules. After coating, the coated granules were lyophilized (Lot#N03-2) and SEM images of the granule were taken.
  • the agitator was set to 150 rpm, and the chopper was set to 300 rpm.
  • the coating process had a duration of 10 minutes.
  • the powder mixture and the surface of coated granules reacted with water, resulting in a third calcium phosphate coating on the ⁇ -TCP granules.
  • the coated granules were lyophilized (Lot#N03-3) and SEM images of the granule were taken.

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