Classifications

• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
  • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
  • A61F2/02—Prostheses implantable into the body
  • A61F2/30—Joints
  • A61F2/46—Special tools for implanting artificial joints
  • A61F2/4684—Trial or dummy prostheses
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
  • A61B17/00—Surgical instruments, devices or methods
  • 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 or setting implements
  • A61B17/88—Osteosynthesis instruments; Methods or means for implanting or extracting internal or external fixation devices
  • A61B17/92—Impactors or extractors, e.g. for removing intramedullary devices
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
  • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
  • A61F2/02—Prostheses implantable into the body
  • A61F2/30—Joints
  • A61F2/38—Joints for elbows or knees
  • A61F2/3859—Femoral components
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
  • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
  • A61F2/02—Prostheses implantable into the body
  • A61F2/30—Joints
  • A61F2/46—Special tools for implanting artificial joints
  • A61F2/4603—Special tools for implanting artificial joints for insertion or extraction of endoprosthetic joints or of accessories thereof
  • A61F2/461—Special tools for implanting artificial joints for insertion or extraction of endoprosthetic joints or of accessories thereof of knees
• • 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
  • A61L27/40—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material
  • A61L27/44—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix
  • A61L27/443—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix with carbon fillers
• • 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
  • A61L27/40—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material
  • A61L27/44—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix
  • A61L27/446—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix with other specific inorganic fillers other than those covered by A61L27/443 or A61L27/46
• • 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
  • A61L27/40—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material
  • A61L27/44—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix
  • A61L27/48—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix with macromolecular fillers
• • 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
  • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
  • A61L31/12—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material
  • A61L31/125—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix
  • A61L31/126—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix containing carbon fillers
• • 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
  • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
  • A61L31/12—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material
  • A61L31/125—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix
  • A61L31/128—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix containing other specific inorganic fillers not covered by A61L31/126 or A61L31/127
• • 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
  • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
  • A61L31/12—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material
  • A61L31/125—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix
  • A61L31/129—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix containing macromolecular fillers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
  • B29C43/006—Pressing and sintering powders, granules or fibres
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
  • A61B17/00—Surgical instruments, devices or methods
  • A61B17/16—Instruments for performing osteoclasis; Drills or chisels for bones; Trepans
  • A61B17/17—Guides or aligning means for drills, mills, pins or wires
  • A61B17/1739—Guides or aligning means for drills, mills, pins or wires specially adapted for particular parts of the body
  • A61B17/1764—Guides or aligning means for drills, mills, pins or wires specially adapted for particular parts of the body for the knee
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
  • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
  • A61F2/02—Prostheses implantable into the body
  • A61F2/30—Joints
  • A61F2/46—Special tools for implanting artificial joints
  • A61F2/4603—Special tools for implanting artificial joints for insertion or extraction of endoprosthetic joints or of accessories thereof
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
  • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
  • A61F2/02—Prostheses implantable into the body
  • A61F2/30—Joints
  • A61F2/38—Joints for elbows or knees
  • A61F2/3859—Femoral components
  • A61F2002/3863—Condyles fitted on an anchored base
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
  • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
  • A61F2/02—Prostheses implantable into the body
  • A61F2/30—Joints
  • A61F2/46—Special tools for implanting artificial joints
  • A61F2002/4681—Special tools for implanting artificial joints by applying mechanical shocks, e.g. by hammering
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
  • A61F2240/00—Manufacturing or designing of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof
  • A61F2240/001—Designing or manufacturing processes
  • A61F2240/007—Dummy prostheses
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
  • B29K2105/16—Fillers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2509/00—Use of inorganic materials not provided for in groups B29K2503/00 - B29K2507/00, as filler
  • B29K2509/08—Glass
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/753—Medical equipment; Accessories therefor

Definitions

• the present invention relates generally to the field of medical instruments and methods, and more particularly relates to surgical instruments, implants, and methods, where the surgical instruments or implants have been manufactured from materials including at least a polymer and a filler material.
• a surgical instrument or implant may require a certain level of material rigidity to adequately transfer force through the surgical instrument or implant.
• An implant may be required to approximate the rigidity of a
• impact resistance and material rigidity characteristics may have an inverse relationship. In many materials, as rigidity goes up so does brittleness, and a brittle material has a lower impact resistance and lower material toughness.
• Improved instruments, implants, and methods may provide for adequately impact resistant and rigid instruments and implants that are constructed from materials that have been evaluated and approved for use as surgical devices.
• An embodiment of the invention is a femoral trial that includes at least a trial instrument made generally in the shape of a femoral component implant that is configured to receive impact for the purpose of seating the trial instrument on a distal end of a femur of a patient.
• the trial instrument may be manufactured at least in part from a medical grade polymer and a filler material capable of increasing the rigidity of the trial instrument when mixed with the medical grade polymer.
• FIG. 1 Another embodiment of the invention is a surgical instrument configured to be sterilized and used to manipulate the tissue of a patient.
• the surgical instrument embodiment includes a surgical instrument body including a force receiving zone that is configured to receive impact to position the surgical instrument within the patient or to manipulate the tissue of the patient.
• the surgical instrument may be manufactured at least in part from a medical grade polymer and a filler material capable of increasing the rigidity of the surgical instrument when mixed with the medical grade polymer.
• Still another embodiment of the invention is a method of constructing a thermoplastic composite material that has the ability to be formed into a surgical instrument that is configured to receive an impact force.
• This method embodiment includes at least obtaining a medical grade polymer, obtaining a filler material capable of increasing the rigidity of the thermoplastic composite material when consolidated with the medical grade polymer, consolidating the medical grade polymer with the filler to create a mixture, and pressing the mixture into a mold constructed in the shape of the surgical instrument configured to receive an impact force.
• Yet another embodiment of the invention is a method of supplying a material acceptable for use as a surgical device.
• This method may include at least providing a polymer cleared for use during a surgical procedure for the benefit of a patient, providing a filler material configured to increase the rigidity of the polymer when consolidated with the polymer, consolidating the polymer with the filler to create a mixture, evaluating the mixture for suitability, and making the material available for use as part of a surgical device.
• FIG. 1 is a perspective view of an embodiment of a femoral trial being placed onto a distal end of a femur.
• FIG. 2 is a perspective view of the femoral trial illustrated in FIG. 1.
• a surgical instrument is a femoral trial 1.
• the femoral trial 1 is being placed onto a distal end of a femur 100.
• the femoral trial 1 is a ream-through femoral trial, which means that the femoral trial 1 is configured to receive a reamer through its central portion such that a patient's femur 100 may be accessed while the femoral trial 1 is in place on the femur 100.
• An impactor 10 is shown receiving an impact force F to drive the femoral trial 1 onto the femur 100.
• This impact force F may be applied by, without limitation, a mallet, a hammer, a slap hammer, an automated impaction tool, or any other tool or device capable of delivering a force to drive the impactor 10 toward the femoral trial 1.
• a force receiving or impaction zone 5 is shown on the femoral trial 1 that corresponds to the area that would receive force from the impactor 10, as illustrated in FIG. 1.
• the femoral trial 1 must be rigid enough to retain its shape when impacted, but impact resistant enough to not fracture when impacted. Material of the femoral trial 1 in and near the impaction zone 5 is particularly susceptible to fracture when impacted.
• the femoral trial 1 is a trial instrument made generally in the shape of a femoral component implant of a total knee arthroplasty device.
• an instrument or implant of the invention may be any component, part, or sub-part of a medical instrument or implant.
• the femoral trial 1 is configured to receive impact, such as the impactor 10, to seat the femoral trial 1 on a distal end of a femur 100 of a patient.
• the illustrated trial instrument, femoral trial 1 is manufactured at least in part from a polymer and a filler material capable of increasing the rigidity of the trial instrument when mixed with the polymer.
• the femoral trial 1 is an instrument for use in an orthopedic procedure, but in other embodiments, an instrument or implant of the invention may be any other medical instrument or implant and may be for any medical procedure.
• An instrument of some embodiments of the invention may be a disposable device.
• an instrument set may include two or more trials of various sizes so that the trials can be placed in contact with a patient's tissue to judge the appropriate size of a device to ultimately be implanted.
• Such instruments may be packaged in sterile packaging or may be delivered for surgery non-sterile and sterilized by surgical staff members. It may be an advantage in some circumstances to provide instruments that can be used intraoperatively and then disposed of, thereby reducing the costs associated with additional cleaning, sterilization, and possibly packaging. This option may also reduce the potential for contaminant or disease transmission by improving the quality and repeatability of sterilization procedures by accomplish these tasks in a more quality controlled environment.
• Sterilization may include steam
• sterilization with an autoclave or sterilization by one or more of the following: ethylene oxide, vaporized hydrogen peroxide, plasma vaporized hydrogen peroxide, electron beam, or gamma radiation. Any other effective sterilization technique may also be used.
• a polymer for use in various embodiments of the invention may include any feasible polymer resin or material.
• Some polymers for use in various embodiments of the invention may particularly be medical grade polymers.
• Medical grade polymers include properties that make the polymers useful in medical procedures.
• Example useful properties, among others, may include non-irritation of a patient's tissue, less susceptibility to leaching, and an absence of an immune response in the presence of the polymer.
• Polymers of some embodiments may be polymers with relatively high temperature resistance characteristics.
• Some polymers of embodiments of the invention may be polycarbonates, which are a particular group of thermoplastic polymers.
• Polycarbonates are polymers containing carbonate groups. Many polycarbonates are derived from rigid monomers, and may have a balance of useful features including temperature resistance, impact resistance, chemical stability, and optical properties. Polycarbonates may have the additional benefit of being less expensive than engineering plastics, although offering many of the same benefits.
• Embodiments of the invention may particularly include Poly (bisphenol-A-carbonate) polycarbonates.
• One example medical grade polymer that is a Poly (bisphenol-A-carbonate) is a product trade named LEXAN (a product of SABIC Innovative Plastics) and has the product identification HPH4404 - 7H6D057T. This material may be referred to as LEXAN HPH4404.
• LEXAN HPH4404 may include base resins that have been approved under one or both of USP Class VI standards and ISO 10993-1 standards.
• USP United States Pharmacopeia
• ISO 10993-1 provides for evaluation and testing of medical devices within a risk management process. The standard looks at the general classification of devices based on their nature and duration of contact with the body. It also explains the evaluation of existing and relevant data from all sources, before identifying information gaps. Best practice recommendations for accomplishing a full assessment of the biological safety of medical instruments and implants are also provided. ISO 10993-1 requires evaluation and testing of non-biological attributes and properties of materials used in medical devices, such as chemical, physical, electrical, morphological and mechanical properties.
• suitable fillers include materials known for combination with polymers generally and polycarbonate specifically, as well as other materials as disclosed herein.
• Fillers may be for reinforcing a composition or for otherwise changing the physical or volumetric characteristics of a composition.
• Suitable fillers may include, without limitation, any reinforcing material or fiber.
• Specific reinforcing fillers include, but are not limited to, carbon fibers, short glass, glass fibers, graphite fibers, polymeric fibers, and aromatic polyimide (aramid) fibers.
• Fillers may include continuous or chopped fibers such as asbestos, carbon, or glass of any type or shape. Fillers may be elongated fibers with lengths five or more times greater than their widths.
• Fillers may also include, without limitation, silicates and silica powders such as aluminum silicate (mullite), synthetic calcium silicate, zirconium silicate, fused silica, crystalline silica graphite, natural silica sand, boron powders such as boron-nitride powder, boron-silicate powders, oxides such as aluminum oxide, zirconium oxide, titanium dioxide, nanoscale titanium oxide, titanium boride, aluminum trihydrate, vanadium oxide, magnesium oxide, calcium sulfate, calcium carbonates such as chalk, limestone, marble, synthetic precipitated calcium carbonates, and talc, including fibrous, modular, needle shaped, lamellar talc.
• silicates and silica powders such as aluminum silicate (mullite), synthetic calcium silicate, zirconium silicate, fused silica, crystalline silica graphite, natural silica sand, boron powders such as boron-nitride powder, boron-silicate
• Fillers may include glass spheres such as hollow and solid glass spheres, silicate spheres, cenospheres, aluminosilicate (armospheres), kaolin, including hard kaolin, soft kaolin, calcined kaolin, kaolin comprising various coatings known in the art to facilitate compatibility with the polymeric matrix resin, single crystal fibers, silicon carbide, alumina, boron carbide, iron, nickel, copper, sulfides such as molybdenum sulfide, zinc sulfide, and barium compounds such as barium titanate, barium ferrite, barium sulfate, heavy spar.
• glass spheres such as hollow and solid glass spheres, silicate spheres, cenospheres, aluminosilicate (armospheres), kaolin, including hard kaolin, soft kaolin, calcined kaolin, kaolin comprising various coatings known in the art to facilitate compatibility with the polymeric matrix resin,
• Fillers may also include metals and metal oxides such as particulate or fibrous aluminum, bronze, zinc, copper and nickel; flaked fillers such as glass flakes, flaked silicon carbide, aluminum diboride, aluminum flakes, steel flakes; fibrous fillers, and inorganic fibers such as those derived from blends comprising at least one of aluminum silicates, aluminum oxides, magnesium oxides, and calcium sulfate
• Fillers may include basalt fibers, carbon nanofibers, carbon nanotubes, carbon buckyballs, ultra high molecular weight polyethylene fibers, melamine fibers, polyamide fibers, potassium titanate whiskers, and aluminum borate whiskers.
• Fillers may also include organic fillers such as polytetrafluoroethylene, organic fibrous fillers formed from organic polymers capable of forming fibers such as poly(ether ketone), polybenzoxazole, poly(phenylene sulfide), polyesters, polyethylene, aromatic polyamides, aromatic polyimides,
• organic fillers such as polytetrafluoroethylene, organic fibrous fillers formed from organic polymers capable of forming fibers such as poly(ether ketone), polybenzoxazole, poly(phenylene sulfide), polyesters, polyethylene, aromatic polyamides, aromatic polyimides,
• polyetherimides polytetrafluoroethylene, acrylic resins, poly (vinyl alcohol), as well as additional fillers such as mica, clay, nano-clay, feldspar, flue dust, fillite, quartz, quartzite, perlite, tripoli, diatomaceous earth, carbon black, or combinations comprising at least one of the foregoing fillers.
• Fillers may be of natural or synthetic, mineral or non-mineral origin, provided that the fillers have sufficient thermal resistance to maintain solid physical structure at least at the processing temperature of the polymer with which it is combined.
• Fillers may also include antimony trioxide, diatomaceous earth, fuller earth, kieselguhr, slate flour, volcanic ash, wollastonite, zinc borate, tungsten carbide, ferrites, molybdenum disulfide, cristobalite, and combinations comprising at least one of any of the fillers listed herein.
• Suitable fillers may be provided in the form of monofilament or multifilament fibers and may be used either alone or in combination with other types of fiber, through any matrix or fibril construction, or by other methods known to one skilled in the art of fiber manufacture.
• Woven or mixed fillers structures may include, for example, glass fiber-carbon fiber, carbon fiber-aramid fiber, and aromatic polyimide fiberglass fiber or the like.
• Fibrous fillers may be supplied, without limitations, in the forms including but not limited to, ravings, woven fibrous reinforcements, non-woven fibrous reinforcements such as continuous strand mat, chopped strand mat, tissues, papers and felts or any three-dimensional reinforcement, such as a braid.
• melt kneading method is a method wherein, with a polymer resin in a molten state, a filler is kneaded into the resin by an extruder.
• a melt kneading method may include one method (a side feeding method) wherein the resin is melted by a twin extruder, and the filler is introduced from a feed inlet.
• Another melt kneading method is a method (a premix method) wherein a resin and a filler that are preliminarily blended by a twin screw or single screw extruder, are melt-kneaded.
• a pultrusion method also may be employed in a case where the form of the filler is a long fiber filler, and the molded product to be obtained is required to have high mechanical strength.
• the pultrusion method is one wherein while continuous long fiber strands are drawn, the resin to form a matrix is impregnated to the fiber strands.
• Pultrusion may also include a method wherein fiber strands are passed through an impregnation bath containing a solution of the matrix resin to impregnate the resin, a method wherein a powder of the matrix resin is sprayed on fiber strands, or fiber strands are passed through a tank containing the powder to attach the matrix resin powder to the fiber strands, and then, the matrix resin is melted and impregnated into the fiber strands, and a method wherein, while fiber strands are passed through a crosshead, the matrix resin is supplied to the crosshead to have the resin impregnated into the fiber strands.
• a polycarbonate resin composition produced by one of these methods may be subjected to a conventional molding method, such as injection molding, extrusion molding, compression molding, or calendaring to obtain a molded product. Further, the molding may be carried out by means of a mold having the interior covered with a resin film or a resin sheet.
• Conditions for production of these types of composite materials, and the condition for molding the composite materials into a molded product can suitably be selected and are not particularly limited.
• a heating temperature during melt kneading or pultrusion processes or a temperature of the resin during injection molding may be within a range of from 220° C to 300° C in order to avoid decomposition of the resin.
• the amount of filler used relative to the amount of polymer used in a mixture may affect the rigidity of the mixture when the mixture is cured.
• References to use of filler material herein include use of a single filler material and combinations of filler materials selected from the fillers specified.
• the filler material comprises from 5 to 60 mass percent of the total mixture of polymer and filler
• significant rigidity improvements to the cured mixture are accomplished without significantly reducing the material toughness of the cured mixture.
• the filler is short glass and the polymer is LEXAN HPH4404.
• Other polymers and fillers in similar proportions are contemplated to have similar properties.
• Another embodiment with effective cured material characteristics is a mixture of polymer with a filler material that is approximately 10 mass percent of the total mixture of polymer and filler. Another embodiment with effective cured material characteristics is a mixture of polymer with a filler material that is approximately 20 mass percent of the total mixture of polymer and filler. Another embodiment with effective cured material characteristics is a mixture of polymer with a filler material that is approximately 30 mass percent of the total mixture of polymer and filler. Another embodiment with effective cured material characteristics is a mixture of polymer with a filler material that is approximately 40 mass percent of the total mixture of polymer and filler. Another embodiment with effective cured material characteristics is a mixture of polymer with a filler material that is approximately 50 mass percent of the total mixture of polymer and filler.
• An embodiment of the invention is a method of constructing a thermoplastic composite material that has the ability to be formed into a surgical instrument that is configured to receive an impact force.
• This method embodiment includes obtaining a polymer, such as any of the polymers referenced herein, including possibly a medical grade polymer.
• the polymer may be a Poly (bisphenol-A-carbonate), and may be LEXAN
• the method also includes obtaining a filler material capable of increasing the rigidity of the thermoplastic composite material when consolidated with the polymer.
• a suitable filler material may be selected from the fillers referenced herein.
• the filler may include a short glass material.
• the polymer and the filler are consolidated to create a mixture.
• This consolidation may include a melt kneading method, a pultrusion method, or any other functional method of consolidating the materials to create a mixture.
• the mixture may be pressed into a mold constructed in the shape of the surgical instrument that is configured to receive an impact force. Pressing of the mixture into the mold may be accomplished by the use of pneumatic, hydraulic, direct, or any sufficient force. Molds of various embodiments of the invention may be made in the shape of practically any desired implant or instrument shape and size.
• a mold may be constructed in the shape of the femoral trial 1 illustrated in FIGS. 1-2.
• the femoral trial 1 includes an impaction zone 5 configured to receive an impact force.
• the femoral trial 1 is configured to receive an impact force at least because of the material toughness of the polymer from which it is partially formed.
• Still other embodiments of the invention include a method of supplying a material acceptable for use as a surgical device.
• a surgical device may include instrument or implant devices.
• Such a method may include providing a polymer cleared for use during a surgical procedure for the benefit of a patient.
• a polymer cleared for use may include one or more of the following: approval from the US FDA, approval in Europe with a CE Mark, approval from a private standards body, approval from any accepted governmental or nongovernmental agency authorized to provide clearance in a particular jurisdiction, and approval in light of a particular clearance protocol.
• a polymer cleared for use may include one or both of a USP Class VI approved base resin and an ISO 10993-1 approved base resin.
• the polymer may be a Polyurethane
• bisphenol-A-carbonate may be LEXAN HPH4404 particularly.
• Such a method may further include providing a filler material configured to increase the rigidity of the polymer when consolidated with the polymer.
• a suitable filler material may be selected from the fillers referenced herein.
• the filler may include a short glass material.
• the method may also include evaluating the mixture for suitability.
• the term mixture includes characteristics of the mixture when cured.
• Such an evaluation may comprise conducting tests and analyses.
• Such an evaluation may also or in the alternative comprise providing information to another person, testing facility, or organization to conduct tests and analyses.
• evaluating the mixture may include supplying one or both of samples and data to another person, testing facility, or organization that will use the samples or data to determine if the mixture is acceptable for use as a surgical device. Evaluation criteria may include inclusion of any desirable characteristic or exclusion of any undesirable
• characteristic for example and without limitation, biocompatibility, material strength, durability, and rigidity.
• the cured mixture comprising the final material is made available for use as a part of or as an entire surgical device.
• This act of making the material available includes making the material available for others to use to make surgical devices and includes using the material to make one's own devices, and then making those devices available for use.
• the act of making the material available would include providing a material for the purchase of others who would manufacture a surgical device.
• the act of making the material available may also include manufacturing components, such as the femoral trial 1 illustrated in FIGS. 1-2, and making the femoral trial 1 available to medical providers.

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• Health & Medical Sciences (AREA)
• Chemical & Material Sciences (AREA)
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• Public Health (AREA)
• General Health & Medical Sciences (AREA)
• Animal Behavior & Ethology (AREA)
• Veterinary Medicine (AREA)
• Engineering & Computer Science (AREA)
• Transplantation (AREA)
• Epidemiology (AREA)
• Oral & Maxillofacial Surgery (AREA)
• Orthopedic Medicine & Surgery (AREA)
• Heart & Thoracic Surgery (AREA)
• Materials Engineering (AREA)
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• Vascular Medicine (AREA)
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• Medicinal Chemistry (AREA)
• Dermatology (AREA)
• Biomedical Technology (AREA)
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• 2014
  • 2014-02-11 EP EP14751715.5A patent/EP2956089A4/en not_active Withdrawn
  • 2014-02-11 RU RU2015138438A patent/RU2015138438A/ru not_active Application Discontinuation
  • 2014-02-11 WO PCT/US2014/015770 patent/WO2014126908A1/en not_active Ceased
  • 2014-02-11 CN CN201480021968.0A patent/CN105120803A/zh active Pending
  • 2014-02-11 US US14/767,788 patent/US20150366677A1/en not_active Abandoned
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  • 2014-02-11 JP JP2015558077A patent/JP2016506857A/ja active Pending
  • 2014-02-11 CA CA2900774A patent/CA2900774A1/en not_active Abandoned
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