WO2005096759A2 - Structures composites tressées - Google Patents

Structures composites tressées Download PDF

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Publication number
WO2005096759A2
WO2005096759A2 PCT/US2005/011172 US2005011172W WO2005096759A2 WO 2005096759 A2 WO2005096759 A2 WO 2005096759A2 US 2005011172 W US2005011172 W US 2005011172W WO 2005096759 A2 WO2005096759 A2 WO 2005096759A2
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WO
WIPO (PCT)
Prior art keywords
composite
thermoplastic
braid
ring
fibrous braid
Prior art date
Application number
PCT/US2005/011172
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English (en)
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WO2005096759A3 (fr
Inventor
Christopher D. Toto
Stephen D. Koehler
Thomas Brice Langston
Original Assignee
Greene, Tweed Of Delaware, Inc.
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Application filed by Greene, Tweed Of Delaware, Inc. filed Critical Greene, Tweed Of Delaware, Inc.
Publication of WO2005096759A2 publication Critical patent/WO2005096759A2/fr
Publication of WO2005096759A3 publication Critical patent/WO2005096759A3/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/56—Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor
    • A61B17/58—Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor for osteosynthesis, e.g. bone plates, screws, setting implements or the like
    • A61B17/60—Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor for osteosynthesis, e.g. bone plates, screws, setting implements or the like for external osteosynthesis, e.g. distractors, contractors
    • A61B17/62—Ring frames, i.e. devices extending around the bones to be positioned

Definitions

  • the repair of traumatized bone or the repair or reshaping of defective bone can be accomplished by the use of an external bone fixator device that often includes a number of curved rings or curved half rings. These rings or half rings are spaced apart and are structurally connected using a plurality of tie rods or other connecting devices, such as wires or cords. These connecting devices may be attached to the ring by insertion in the rings through holes present in each of the rings or half rings and or by threading the connectors through hooks, rivets or loops that are affixed to the rings or half rings.
  • curved rings, half rings, and/or connectors are used in the "Ilizarov" method of external fixation of severely damaged or severely traumatized bone.
  • the Ilizarov method can be used for lengthening various congenital and acquired shortenings and other defects of skeletal segments wherein the rings and tie rods form part of a compression distraction apparatus.
  • the rings and connectors of many bone fixation and other medical devices are made of metal.
  • Metals are amenable to sterilization procedures (by heat or chemical agents) and are non-antigenic.
  • Metals also possess the physical properties necessary for many bone fixator apparatuses, for bone or body stabilization apparatuses (such as halos) or for other medical devices, such as strength and a relatively high flexural modulus, for example, 10,000,000 pounds per square inch (psi) (68,948 MPa) for aluminum.
  • metals while useful, have some disadvantages in such applications. Metal apparatuses can be heavy and consequently unwieldy, potentially hindering a surgeon's dexterity in device insertion or manipulation during a procedure.
  • a patient fitted with a metal-containing device may experience additional discomfort because of the mass of the device, the cold feeling of metal against the skin, and/or the potential for certain types of metal to discolor or irritate the skin. More significantly when considered from the perspective of patient care, metal is not radio-opaque. Bone fixators or other devices secured to a patient may obstruct the passage of diagnostic X-rays, potentially hindering the physician in diagnosis and treatment of the patient. [0006] Plastics (including thermoplastic and thermoset) are generally radiolucent, can be subjected to most sterilization procedures, and do not provoke immune responses in humans. They are not, however, feasible replacements for the rings and half rings used in bone fixators and other medical devices as most do not possess desired tensile strength and flexural modulus properties comparable to metal.
  • the invention includes a composite comprising a polymer selected from the group consisting of a thermoplastic and a thermosetting polymer; and a fibrous braid; wherein the fibrous braid is impregnated with the polymer and the composite is capable of being machined.
  • the invention further includes a composite comprising a fibrous braid comprising at least one commingled yarn, wherein the at least one commingled yarn comprises thermoplastic fibers and carbon fibers, wherein the fibrous braid is heated and consolidated to form the composite and the composite is capable of having at least one aperture machined therethrough.
  • a method of forming a composite structure is also within the scope of the invention and comprises providing a fibrous braid formed by at least one yarn, providing a thermoplastic, applying heat to the fibrous braid and the thermoplastic to impregnate the fibrous braid and to form the composite structure, and machining the composite structure.
  • One embodiment includes an orthopedic ring comprising a composite that comprises a thermoplastic and a fibrous braid, wherein the braid is impregnated with the thermoplastic the composite is capable of being machined, wherein the composite has a configuration of an orthopedic ring having at least one aperture extending longitudinally therethrough.
  • a composite comprising a thermoplastic polymer; and a fibrous braid; wherein the fibrous braid is impregnated with the thermoplastic and the composite is capable of being machined.
  • FIG. 1 is a top plan view of an embodiment of a ring portion as described herein;
  • Fig. 2 is a cross-sectional view of the ring portion in Fig. 1 taken along the line 2-2;
  • FIG. 3 a is a perspective view of the ring portion of Fig. 1;
  • Fig. 3b is a perspective view of a ring portion described herein;
  • Fig. 4 is a photograph of non-limiting examples commingled yarns that include polyetheretherketone fibers and carbon fibers;
  • FIG. 5 is a photograph of a top view of a fibrous braid useful for forming composites as described herein; [0021] Fig. 5a is a magnified view of the fibrous braid of Fig. 5;
  • Fig. 5b is a perspective view of a fibrous braid
  • Fig. 6 is a braiding diagram as described in the specification and referred herein in the Examples.
  • Fig. 7 is a perspective view of orthopedic rings or ring portions as described herein incorporated into a non-limiting example of an orthopedic brace on a patient.
  • the present invention includes many embodiments of composites for medical and other uses.
  • the composites are useful for a variety of applications including, without limitation, aerospace applications; medical devices and tools, such as halos, X-ray cassettes, nail guides, X- ray accessories, bone fixators of all types, bone screws, bone plates, stabilizers, braces, structural components of casts; surgical tools such as drills, scalpels, forceps, tweezers, and retractors.
  • Other potential applications include use of the composites to make parts for use in fluid handling applications, industrial applications, biotechnological applications, oilfield applications, semiconductor applications and shipping containers.
  • the composite will be described herein with respect to rings or ring portions that can be used in orthopedic braces or bone fixation devices.
  • the composite can be used to form a wide variety of shapes.
  • the composite may be made of a thermoplastic polymer or a thermosetting polymer, but is preferably formed from thermoplastic polymer.
  • the composite as described in one preferred embodiment includes at least one thermoplastic.
  • thermoplastics include polyethylene, polyethylene chlorinates, polyaryl ether ketones (such as polyetherketone, polyetherketoneketone and polyetheretherketone), polyamides (such as NYLON 6, NYLON 12), acrylonitrile-butadiene-styrene (ABS), cellulosic resins (such as ethyl cellulose, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, and cellulose nitrate), ethylene vinyl alcohol, fluoroplastics (such as polytetrafluoroethylene (PTFE), fluorinated ethylene propylene copolymer (FEP), perfluoro-alkylalkane (PFA), poly(chlorotrifluoroethylene), ethyl chlorotrifluoroethylene (ECTFE), ethyltrifluoroethylene (ETFE), and polyvinylidene fluoride (PVDF), polyvinyl chlorides (PVC),
  • the preferred thermoplastics include polyaryl ether ketones (such as polyetherketone, polyetherketoneketone and polyetheretherketone), sulfones (such as polysulfone, polyethersulfone and polyphenylsulfone), and polyphenylene sulfides and/or copolymers and/or derivatives and/or combinations of these or any other known or to be developed thermoplastics.
  • the composite may also include combinations or blends of one or more of the above thermoplastics.
  • impregnated it is meant that the thermoplastic is incorporated intimately into the braid by any acceptable process.
  • the thermoplastic may be incorporated into the braid as a thermoplastic fiber within a yarn or commingled yarn and then heated and consolidated.
  • the thermoplastic can be incorporated into the fibrous braid by injection molding or distributed within the braid as powder or pellets which can be heated and consolidated and/or compression molded into the fibrous braid.
  • the thermoplastic can also be incorporated by a combination of these techniques.
  • the composite has a continuous structure that is formed from entwining at least one yarn. Entwining can be accomplished by any means known in the art, such as knitting, weaving, twisting or braiding. Braiding is preferred.
  • thermoplastic may be part of the braid initially as shown in Figure 5 as yarn including thermoplastic fiber(s), or it can be added in powder, pellet, or liquid form, or both.
  • a braid can be made from at least one yarn. No particular method of braiding is required. Braiding may be accomplished by any technique known in the art or to be developed and may be carried out by use of a machine or by hand. Suitable braiding machines include those disclosed in, for example, but not limited to U.S. Patents No. 4,719,837 and No. 5,320,696, the relevant contents of each of which are incorporated herein by reference.
  • the braid may be of any type known in the art, for example, but not limited to, a flat braid, a square braid, a diagonal braid, a sock braid, a cable braid, a tubular braid, a guilloche braid, a corded braid, and a ply-split braid.
  • One embodiment includes a braid that is constructed around another braid so that the complete braid is actually formed of one or more layers of braids.
  • Another possibility includes using a combination of braids such as using two or more flat braids.
  • the transverse cross-section of the braid can be of any shape such as substantially rectangular, substantially polygonal, substantially triangular, substantially octagonal, substantially circular, substantially semicircular, substantially ovoid, and substantially square.
  • the longitudinal direction of the braid is defined herein as taken along the length of the braid and the transverse cross-section is defined as being perpendicular to the longitudinal direction. It is preferred that the transverse cross-sections of the braid are substantially square. Substantially square is broadly defined herein, as are all of the shapes, and includes transverse cross-sections with rounded or defined edges or corners and edges that may be convex and/or concave.
  • Braids can be prepared with any number, types, or combination of yarns.
  • Non- limiting examples of braid forming machinery include the type that follows a braid track diagram and a horn gear arrangement.
  • Braid track diagrams can be in many different shapes and forms.
  • the braid track diagram of Figure 6 includes two substantially rectangular shapes of one size (long and thin) and two substantially rectangular shapes of another size (about three times thicker and about 30% shorter than the longer, thinner rectangles).
  • the long and thin rectangles 10, 12 are positioned in a perpendicular fashion with respect to each other so as to form an "X.”
  • the long and thin rectangles are also known as the outside tracks 10, 12.
  • the thicker rectangles 14, 16 are positioned in a perpendicular fashion with respect to each other so as to form an X-like shape.
  • the thicker rectangles are also known as the inside tracks 14, 16.
  • the two "X's" are then placed on top of each other and their edges are parallel to one another so as to form a grid, which is the braid track diagram.
  • the braid track diagram in Figure 6 is comprised of 4 tracks and 25 grid units.
  • the grid units are labeled with alphanumeric designations (e.g. Al, B4, E7, and so on).
  • a carrier contains one or more spools.
  • the spools supply the yam(s) that feed into the braid and a spool may contain one or more yams. Therefore, each carrier can supply one or more yams (also known as ends) at a time.
  • one or more axial yams which remain stationary, may also be fed from any one or more of the grid units. If axial yam is fed through the grid units, one or more yams can be supplied up through the grid unit from additional spools.
  • the yams fed from the carriers and from the grid units need not be all the same kind of yam. Different yams can be used when braiding, including at least two or more commingled yams 18a, 18b, 18c, non-limiting examples of which are included in Figure 4.
  • the yams are fed through to a die (not shown), which primarily holds the braid in place.
  • the "tightness" of the braid can be altered by manipulating gear ratios.
  • the gear ratio affects the angle of the ya s within the braid itself. Also, the gear ratio determines how the yam fibers will wear against each other. The gear ratio varies with the type of yam that is used, the machine employed, and the end application of the braid.
  • Positioning of the axial yams depends a great deal on the configuration of the desired end product.
  • the desired end product is to have two ring portions that have mating ends that are capable of coupling in such a way so as to create a full ring and so that the top faces of the respective ring portions are flush with each other and the respective bottom faces of the ring portions are flush with each other, thereby creating a smooth surface on each face of the resulting ring in the longitudinal direction.
  • a non-limiting example includes the end of a first ring portion that can be machined so as to create a void in order to accept a protrusion or a tab from the end of a second ring portion.
  • Another non-limiting example includes a configuration where the ends of each ring portion are machined so as to create a combination of a stepped void and a tabular protrusion on each end so that the ends of the two ring portions can mate by having the tabular protrusion of one ring portion occupy the stepped void of the mating ring.
  • Axial yams or extra axial yams may be placed in the area of the braid that will correspond to the protrusion of the end of the ring portion so as to provide added strength to the protrusion.
  • the braid can be of any desired dimension. It will depend on the end application and 1 the size required to determine the braid dimensions to use.
  • Each of the dimensions with respect to width and/or height may, as a non-limiting example, be up to and including about 1 inch (2.54 cm).
  • the width or height be independently selected of about 0.5 inches to about 1.75 inches (about 1.27 cm to about 4.44 cm), about 0.7 to about 1.13 inches (about 1.78 cm to about 2.87 cm) and about 0.8 inches to about 1.0 inches (about 2.03 cm to about 2.54 cm).
  • At least one yam is used to prepare the fibrous braid, although the number of yams will vary depending on the size, thickness, and/or use of the ring or ring portion, as well as the diameter and/or material of the yams selected.
  • the braid is formed from 100 to 300 yams, 500 to 1,500 yams, 1,000 to 2,000 yams, 2,000 to 3,000 yams, 3,000 to 5,000 yams, 5,000 to 6,500 yams and greater than 6,000 yams.
  • the yam(s) may be constructed of any type or types of fibers including staple fibers, continuous fibers, and/or thermoplastic fibers. Staple fibers and continuous fibers may be made from carbon, graphite, glass (including fiberglass), and/or ceramic.
  • Thermoplastic fibers can be formed from any of the thermoplastics referenced above. Yams that include fibers of two or more materials are considered to be commingled yams, for example thermoplastic fibers and carbon fibers. Commingled ya s are preferred.
  • Figure 4 is a photograph of a non-limiting example of commingled yams 18a, 18b, 18c.
  • Figure 5 and 5 a are photographs of a section of braid that includes commingled yams. It is preferred that the yams are commingled yams that include at least one carbon fiber and at least one thermoplastic fiber. As a non-limiting example, the commingled yams may include carbon fibers and polyphenylene sulfide fibers. Another non-limiting example of a commingled yam is carbon fibers and polyetheretherketone fibers.
  • a TM noh-Ti ' ihiting " example of carbon fiber presence in a commingled yam may range from about 20 wt % to about 77 wt % carbon fibers. Preferably the range of carbon fiber presence is from about 40 wt % to about 73 wt %. More preferably the range of carbon fiber presence with a commingled yam is from about 50 wt % to about 70 wt %. [0042] The selected yams may be of any diameter.
  • the braid need not be composed of yams that are all of an identical diameter.
  • the diameter of the yam selected will vary depending on several factors including, the size, thickness, and/or use of the ring or ring portion, as well as the material of the yams. It is preferred that the yams have a diameter of about 0.1 to about 20 microns, with about 1 to about 15 microns being more preferred and about 5 to about 10 microns being most preferred. However, yams with diameters of about 0.1 to about 100 microns may be used.
  • Yams can be used in the braid with a linear weight of about 500 to about 3,600 metric count (meters/kg).
  • the linear weight ranges from about 750 to about 2,200 metric count. More preferably the linear weight ranges from about 1,400 to about 2,100 metric count. All of the yams used need not be of the same weight and yams of different weights may be used in the same braid.
  • the composite can also include various additives depending on the intended use. Non-limiting examples of additives include colorants, flame retardants, stabilizers, plasticizers, conductive materials, fillers, ultraviolet absorbers, and other reinforcing fibers or powders.
  • Exemplary fillers or additives may include but are not limited to glass spheres and/or fibers, carbon spheres and/or fibers, carbon black, silicates, fiberglass, calcium sulfate, asbestos, boron fibers, ceramic fibers, polyamide fibers (such as those sold under the trademark KEVLAR ® , available from E.I.
  • the ring or ring portion may also include one or more coating layer(s) of thermosetting or thermoplastic polymer.
  • thermosetting polymers useful as a base polymer and/or a secondary polymer or as additives in the composites of the invention may include epoxy resins, phenolic resins, urea-formaldehyde resins, melamine- formaldehyde resins, polybenzoxazole resins, acetylene terminated polyimide resins, silicones, triazines, alkyds, vinyl ester resins, vinyl esters, and xylene resins and/or copolymers and/or derivatives of these or any other known or to be developed thermosetting resins.
  • a composite structure as described herein can be formed by any method using any apparatus that has the ability to mold the braid into a structure of any desired shape, depending on the intended end use known in the art or to be developed.
  • the braid and thermoplastic is heated and consolidated to form a composite structure.
  • the braid and thermoplastic are compression molded under application of heat to form the braid into a ring or a ring portion.
  • the braid may be placed in the cavity of a compression mold configured in the form of a ring or ring portion. If there is excess braid, it is preferably trimmed such that the length of the braid is approximately the same as the perimeter of the mold cavity.
  • the braid and thermoplastics are then compression molded at a temperature and dwell time suitable for the selected thermoplastic.
  • thermoplastic is present in the braid in the form of a fiber then only the braid will be compression molded, if no further thermoplastics are to be added.
  • the thermoplastic is preferably present in the form of one or more yams which are commingled within the braid, such as polyphenylene sulfide fiber commingled with carbon fibers, the molding should be carried out at a pressure of about 230 psi (1.58 MPa) and at a temperature of about 640°F (337.8°C).
  • the molding should be carried out at a pressure of about 160 psi (1.10 MPa) and a temperature of about 450°F (232.2°C).
  • the resulting composite structure is substantially uniform in appearance in the longitudinal and transverse directions due to the even distribution of the polymer, preferably of the thermoplastic. If there are any fiber fragments or continuous fibers used, it is preferred that they are evenly dispersed throughout the composite structure. Likewise, if there are any fillers, it is preferred that they are evenly distributed.
  • thermoplastics are amenable to being reformed or remolded if a piece would happen to break off or if the desired shape needed to be adjusted. Being reformed is defined as reheating and/or reconsolidating the composite structure in order to (re)create a refurbished or new composite structure.
  • the temperatures and pressures used are the molding temperatures that are suitable to the particular thermoplastic that is in the composite. More thermoplastic and or fibers may be added to fill in any voids. This reduces waste and can be a cost savings measure.
  • thermoplastics listed above allow the composite to be sterilized using steam and/or heat and/or autoclaving without compromising the mechanical performance or affecting the dimensional characteristics (will not deform) of the composite structure.
  • the preferred thermoplastics are amenable to steam sterilization and/or autoclaving because they are generally hydrophobic and will not deform (such as swell, warp, etc.) or degrade from being exposed to steam, thereby maintaining their mechanical performance. Having a composite that is amenable to steam sterilization or autoclaving is especially important in medical device applications. This also allows the composite structure to be reused.
  • Autoclaving typically takes place at temperatures that range from about 265°F (129.4°C) to about 280°F (137.8°C) and at pressures from about 17 psi (1.16 atm) to about 29.4 psi (2 atm).
  • the resulting composite can be molded into any desired shape.
  • One embodiment of the present invention, for purpose of illustration, herein includes a braid that is molded into a ring or ring portion composite structure.
  • ring as used herein, it is meant any structure having a configuration such that the structure has substantially continuous inner and outer perimeters and the inner perimeter defined as an annular space.
  • the ring need not have a generally circular outer and inner perimeter configuration, but may resemble any closed geometric shape - it may be, for example, square, polygonal, ovoid, elliptical or triangular in shape, or any approximation of these geometries.
  • the inner and outer perimeters of the ring when preferably of similar geometries could have differing configurations.
  • FIG. 1 and 3 a A non-limiting example of a ring portion is shown in Figures 1 and 3 a.
  • the ring portions are preferably designed so that they are able to releasably interlock or become releasably attached using connecting devices or by other techniques so as to form an entire ring structure a part of a ring structure or an orthopedic brace forming using such rings or ring portions.
  • the ring portions are preferably configured using a mold, but may also be instead of or in addition to molding, machined from a larger ring portion or larger composite structure.
  • An embodiment of the composite structure as a ring 20 is shown in Figure 3b and as a ring portion 22 is shown in Figures 1 and 3 a.
  • the transverse cross-section of the composite structure shown is a circular ring 20.
  • the transverse cross-section of the composite structure can also be a circular ring portion 22.
  • the transverse direction is defined along the T'-T' axis and T-T axis as shown respectively in Figures 3a and 3b.
  • the longitudinal direction is defined herein with respect to regarding the ring 20 and ring portion 22 as being in the direction of the A'- A' axis and A-A axis, respectively.
  • the composite structure is capable of being machined, such that the edges can be beveled or smoothed, end mitered, or one or more apertures can be inserted in the ring.
  • the ring or ring portions may have aperture(s) or other openings or features for use in the connecting the rings or ring portions.
  • the apertures may be formed through the molding process or preferably when using a braid composite, they are machined.
  • apertures may be machined in the ring or ring portion in order for ties and connectors to be inserted.
  • the apertures need not be circular in shape.
  • the aperture can be in the shape of an arc or elongated hole and/or be threaded.
  • at least one of the substantially circular apertures 24 are formed in the composite structure so as to extend longitudinally therethrough.
  • At least one aperture may be threaded to as to accept a screw or a bolt like member or other similar device that has male threads.
  • hooks, loops or other fixation devices may be secured to the ring or ring portion.
  • One skilled in the art will be able to determine, depending on use and structural integrity, a maximum desired size or diameter for any aperture.
  • Alternative means of formation may also be used.
  • the ring can be formed by attaching the two ends of a ring portion with the two ends of another ring portion with an epoxy, adhesive, or other fixative, and heat curing the preformed structure.
  • thermosetting polymer a thermosetting polymer and a fibrous braid
  • the basic idea as the thermoplastic, described above, is followed, with a few adjustments, which are as follows. If a thermosetting polymer is used to create the composite, the fibrous braid will only consist of fibers that include carbon, glass (including fiber), graphite, and ceramic. Commingled yams generally are not used with the thermosetting polymer, however it may be and can be used in some applications. Any of the thermosetting polymers described above may be used.
  • the fibrous braid is impregnated with the thermosetting polymer by placing the braid into a suitable mold and then pouring the thermosetting polymer in liquid form into the mold, thereby wetting the braid and then applying heat and/or pressure to the fibrous braid and the thermosetting polymer to form the thermosetting polymer composite.
  • the present invention also includes a method of forming a composite structure, as defined above, which includes providing a fibrous braid that is formed from at least one yam and a thermoplastic, applying heat to the fibrous braid and thermoplastic to form the composite structure, and machining the composite structure.
  • the fibrous braid used in the method of forming a composite structure is preferably the braid that is described hereinabove.
  • the braid may be constructed on site, shipped from another site, or it may come from a supplier.
  • Heat is applied to the braid and thermoplastic in order to form the composite structure.
  • the composite structure is formed in a compression molding apparatus. As described above, the temperature and pressure used will depend on the materials selected for inclusion in the composite structure.
  • the composite structure After the composite structure is formed, it can then be machined if necessary in the manner described above.
  • the resulting transverse cross section of the composite structure is a ring or ring portion. If (an) aperture(s) is (are) to be placed within the ring or ring portion, the aperture(s) may be formed when being molded or may be machined into the ring or ring portion. It is preferred that the aperture(s) be machined into the ring or ring portion.
  • Another aspect of the invention includes an orthopedic ring or ring portion 30 that is suitable for use in an orthopedic brace 32, as shown in Figure 7.
  • the ring or ring portion is preferably made from a composite that includes a fibrous braid preferably formed from commingled yams that include thermoplastic fibers and carbon fibers and then formed by heat molding into a composite structure having a desired ring or ring portion configuration.
  • the ring or ring portion is preferably capable of being machined and preferably has at least one aperture 24 that extends longitudinally therethrough.
  • the fibrous braid may be made to have the same construction and use the same material as those described above.
  • the fibrous braid includes commingled yams with one or more thermoplastic fibers and one or more carbon fibers.
  • the thermoplastic can be a combination, copolymer or blend of any of the thermoplastics listed above or their derivatives.
  • the preferred thermoplastics include polyaryl ether ketones, polyether sulfones, polysulfones, polyphenylene sulfides, and combinations and derivatives and copolymers thereof. Creating the orthopedic ring or ring portion using these preferred thermoplastics allows the orthopedic ring or ring portion to be amenable to sterilization, such as by autoclaving, as discussed above.
  • the fibrous braid is transformed into the composite by a suitable heat and pressure, which is determined by the type of thermoplastic that is used. Preferably compression molding is used. When finished the composite is in the form of a basic ring or ring shape. The basic ring or ring portion shape may then be further machined into the orthopedic ring, such as by adding aperture(s). [0063]
  • the orthopedic ring or ring portion preferably has at least one aperture.
  • the aperture can be formed by machining in the orthopedic ring.
  • the at least one aperture extends in the longitudinal direction.
  • the aperture can be of any shape, as discussed above.
  • the aperture is substantially circular.
  • the aperture can be of any diameter as discussed in detail above.
  • a preferred embodiment includes an aperture that is threaded by machining.
  • the aperture is machined in such a way as to allow the aperture to accept bolt-like and screw-like devices or fittings or any device that includes a mating thread.
  • the orthopedic ring or orthopedic ring portions can be used with other orthopedic rings or orthopedic ring portions in any suitable orthopedic device.
  • the orthopedic ring portions can be attached to other orthopedic ring portions to create a Ml orthopedic ring.
  • One embodiment includes, as shown in Figure 7, the orthopedic rings being constructed of at least two ring portions where the ends of the two ring portions are fastened together at a point 34.
  • One way of having the ring portions fasten together includes having the ends of the two ring portions overlap so as to form a circular ring and so that the apertures of each ring portion match up in such a way that a bolt or bolt like device or tie rod can be inserted into the lined-up apertures of the ring portions and then secured with a nut or cap like device.
  • Washers or washerlike devices may be used to help fasten and secure the bolt like device to the ring portions. Having ring portions come together to make a ring around a limb allows the brace to be constructed without requiring movement of the limb. Additional supports or tie rods can be attached to the other parts of the ring or ring portions to create the orthopedic structure as shown in Figure 7.
  • Example 1 Commingled yams of carbon fibers and polyetheretherketone (PEEK) fibers were obtained and loaded onto a conventional 3-D braider machine (a Rockwell 36 Carrier Lattice Braider was used in this example) having 36 carriers, a gear ratio of 26 to 70, and a die size of 1 inch (2.54 cm).
  • the braider was oriented so that the inside tracks 14, 16 had 10 carriers each on track. Each carrier contained one spool and there were 10 yams per spool.
  • the inside tracks 10, 12 had 8 carriers on each track. Each carrier on the inside track contained one spool and and there were 10 yams per spool.
  • the outside comers (Al, A7, Gl, G7) contained 0 spools and 0 yams and the inside comers (C3, C5, E3, E5) varied.
  • the braider was operated in accordance with standard techniques.
  • the resultant braid had a cross-section that varied along the length of the braid with height and width measurements ranging from about 0.75 inches to about 1.0 inches (about 1.90 cm to about 2.54 cm).
  • Commingled yams of carbon fibers and NYLON- 12 were obtained and loaded onto a conventional 3-D braider machine as described in Example 1 but having 20 carriers, a gear ratio of 44 to 52, and a die size of 3/8 inches (0.9525 cm).
  • the braider had the same orientation as that in Example 1.
  • the outside comers (Al, A7, Gl, G7) contained 4 spools and 2 ya s per spool and the inside comers (C3, C5, E3, E5) 4 spools, 10 yams per spool.
  • the braider was operated in accordance with standard techniques.
  • the resultant braid had a cross section with an height measurement Of about 0.385 inches to about 0.415 inches (about 0.98 cm to about 1.05 cm) and a width measurement of about 0.355 inches to about 0.385 inches (about 0.90 cm to about 0.98 cm).
  • Braid B - 4 yams in each axial position labeled B4, D2, D6, and F4.
  • Braid C - 4 yams in each axial position labeled Al, A7, Gl, G7, B4, D2, D6, and F4.
  • the transverse cross-section of the braids varied in width and height from about 0.875 inches (2.22 cm) to about 1.125 inches (2.86 cm) along the length of the braid.
  • the transverse cross-section of the braids varied in width and height from about 1.0 inch (2.54 cm) to about 1.25 inches (3.175 cm) along the length of the braid.
  • Each of the braids result in substantially square transverse cross-sectional shapes.
  • the transverse cross-section of the braid may have right and left sides that are concave on the sides and convex on the upper and lower sides.
  • the shape of the cross-section of the braid is dependent upon the amount of and positioning of the axial yams. Braids with axial yams result in composites with a greater strength than those braids that are without axial yams.
  • thermoplastic composites show advantages over the prior metallic rings and devices.
  • Composites constructed from fibrous braids that are impregnated with thermoplastic are light weight and radiolucent, which are excellent properties for use in medical applications such as orthopedic braces and bone fixation devices, yet their properties are such that they have the desired physical properties to be used in such applications. Additionally, thermoplastic composites do not feel as cold as metal upon contact with the skin, which is an additional benefit, especially in the design of orthopedic braces and bone fixation devices.

Landscapes

  • Health & Medical Sciences (AREA)
  • Orthopedic Medicine & Surgery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Surgery (AREA)
  • Medical Informatics (AREA)
  • Engineering & Computer Science (AREA)
  • Biomedical Technology (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Nuclear Medicine, Radiotherapy & Molecular Imaging (AREA)
  • Molecular Biology (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Materials For Medical Uses (AREA)
  • Braiding, Manufacturing Of Bobbin-Net Or Lace, And Manufacturing Of Nets By Knotting (AREA)

Abstract

L'invention concerne une tresse fibreuse imprégnée d'un polymère thermoplastique et/ou thermodurcissable, qui est chauffée afin de former un composite susceptible d'offrir une grande variété d'utilisations. Le composite résultant peut être usiné; il peut en outre servir à former des bagues ou des parties de bagues qui sont translucides aux rayons X et que l'on peut utiliser dans des appareils orthopédiques et des fixateurs d'os.
PCT/US2005/011172 2004-04-01 2005-04-01 Structures composites tressées WO2005096759A2 (fr)

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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005096759A3 (fr) * 2004-04-01 2006-06-22 Greene Tweed Inc Structures composites tressées
WO2008036034A1 (fr) * 2006-09-19 2008-03-27 Centri Ab Produit prothétique comprenant une paroi en matériau composite et son procédé de fabrication
US7985192B2 (en) 2004-09-09 2011-07-26 Fastform Research Limited Geometrically apertured protective and/or splint device comprising a re-mouldable thermoplastic material
US8592531B2 (en) 2007-09-11 2013-11-26 Solvay Advanced Polymers, L.L.C. Prosthetic devices
CN108125713A (zh) * 2017-12-28 2018-06-08 武汉康斯泰德科技有限公司 长链碳纤维peek外包裹热成型骨固定板及成型方法
US10555827B2 (en) 2014-12-12 2020-02-11 Fastform Research Ltd. Multifunctional orthosis device and method of use
RU2758650C1 (ru) * 2021-01-22 2021-11-01 федеральное государственное бюджетное учреждение "Национальный медицинский исследовательский центр травматологии и ортопедии имени академика Г.А. Илизарова" Министерства здравоохранения Российской Федерации Композитная опора для устройства внешней скелетной фиксации
RU216076U1 (ru) * 2022-07-25 2023-01-16 федеральное государственное бюджетное образовательное учреждение высшего образования "Самарский государственный аграрный университет" Спице-штифтовый аппарат для наружной фиксации переломов бедренной кости у собак средних и крупных размеров

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5472607A (en) * 1993-12-20 1995-12-05 Zenon Environmental Inc. Hollow fiber semipermeable membrane of tubular braid
US5827201A (en) * 1996-07-26 1998-10-27 Target Therapeutics, Inc. Micro-braided guidewire

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005096759A2 (fr) * 2004-04-01 2005-10-20 Greene, Tweed Of Delaware, Inc. Structures composites tressées

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5472607A (en) * 1993-12-20 1995-12-05 Zenon Environmental Inc. Hollow fiber semipermeable membrane of tubular braid
US5827201A (en) * 1996-07-26 1998-10-27 Target Therapeutics, Inc. Micro-braided guidewire

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005096759A3 (fr) * 2004-04-01 2006-06-22 Greene Tweed Inc Structures composites tressées
US7985192B2 (en) 2004-09-09 2011-07-26 Fastform Research Limited Geometrically apertured protective and/or splint device comprising a re-mouldable thermoplastic material
WO2008036034A1 (fr) * 2006-09-19 2008-03-27 Centri Ab Produit prothétique comprenant une paroi en matériau composite et son procédé de fabrication
US8592531B2 (en) 2007-09-11 2013-11-26 Solvay Advanced Polymers, L.L.C. Prosthetic devices
US9144628B2 (en) 2007-09-11 2015-09-29 Solvay Specialty Polymers Usa, Llc Prosthetic devices
US9539361B2 (en) 2007-09-11 2017-01-10 Solvay Specialty Polymers Usa, L.L.C. Prosthetic devices
US10555827B2 (en) 2014-12-12 2020-02-11 Fastform Research Ltd. Multifunctional orthosis device and method of use
CN108125713A (zh) * 2017-12-28 2018-06-08 武汉康斯泰德科技有限公司 长链碳纤维peek外包裹热成型骨固定板及成型方法
CN108125713B (zh) * 2017-12-28 2024-02-23 武汉康斯泰德科技有限公司 长链碳纤维peek外包裹热成型骨固定板及成型方法
RU2758650C1 (ru) * 2021-01-22 2021-11-01 федеральное государственное бюджетное учреждение "Национальный медицинский исследовательский центр травматологии и ортопедии имени академика Г.А. Илизарова" Министерства здравоохранения Российской Федерации Композитная опора для устройства внешней скелетной фиксации
RU216076U1 (ru) * 2022-07-25 2023-01-16 федеральное государственное бюджетное образовательное учреждение высшего образования "Самарский государственный аграрный университет" Спице-штифтовый аппарат для наружной фиксации переломов бедренной кости у собак средних и крупных размеров
RU2810435C1 (ru) * 2023-05-12 2023-12-27 Общество с ограниченной ответственностью "КАРБОНТЕКС" Способ создания конструкционного сектора кольца аппарата Илизарова

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