WO2022054743A1 - グラフト層の形成方法、複合体の製造方法およびグラフト層を形成するための処理液 - Google Patents
グラフト層の形成方法、複合体の製造方法およびグラフト層を形成するための処理液 Download PDFInfo
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- WO2022054743A1 WO2022054743A1 PCT/JP2021/032589 JP2021032589W WO2022054743A1 WO 2022054743 A1 WO2022054743 A1 WO 2022054743A1 JP 2021032589 W JP2021032589 W JP 2021032589W WO 2022054743 A1 WO2022054743 A1 WO 2022054743A1
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- compound
- graft
- treatment liquid
- graft layer
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Classifications
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/12—Chemical modification
- C08J7/16—Chemical modification with polymerisable compounds
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/12—Chemical modification
- C08J7/16—Chemical modification with polymerisable compounds
- C08J7/18—Chemical modification with polymerisable compounds using wave energy or particle radiation
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- 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
- A61L27/14—Macromolecular materials
- A61L27/16—Macromolecular materials obtained by reactions only involving carbon-to-carbon unsaturated bonds
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- 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
- A61L27/14—Macromolecular materials
- A61L27/18—Macromolecular materials obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
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- A—HUMAN NECESSITIES
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- 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
- A61L27/34—Macromolecular materials
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F255/00—Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00
- C08F255/02—Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00 on to polymers of olefins having two or three carbon atoms
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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
- A61L2430/00—Materials or treatment for tissue regeneration
- A61L2430/24—Materials or treatment for tissue regeneration for joint reconstruction
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2351/00—Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers
- C08J2351/06—Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
Definitions
- the present disclosure relates to a method for forming a graft layer, a method for producing a complex, and a treatment liquid for forming a graft layer.
- a technique for forming a polymer film by graft-polymerizing a compound on the surface of a base material is known. Further, a method of forming a polymer film using a treated aqueous solution containing a water-soluble inorganic salt is known.
- the method for forming a graft layer includes a contacting step of bringing a substrate containing the polymer A into contact with a treatment liquid containing the compound B and the polymer C in the solvent D.
- the contacting step includes a polymerization step of graft-polymerizing the compound B with respect to the polymer A constituting at least a part of the surface of the base material.
- the treatment liquid according to one aspect of the present disclosure contains the compound B and the polymer C in the solvent D, and the graft layer in which the compound B is graft-polymerized on at least a part of the surface of the substrate containing the polymer A. It is a treatment liquid for forming.
- the method for forming a graft layer includes a contacting step of bringing a substrate containing the polymer A into contact with a treatment liquid containing the compound B and the polymer C in the solvent D.
- the contacting step includes a polymerization step of graft-polymerizing the compound B with respect to the polymer A constituting at least a part of the surface of the base material.
- the polymer obtained by polymerizing compound B is referred to as "polymer B".
- the “graft layer” means a layer formed by graft-polymerizing the polymer B on the substrate.
- the graft layer is a layer containing the polymer B formed on the surface of the base material.
- the graft-polymerized polymer B is also referred to as a “graft chain”.
- a graft layer containing the polymer B can be efficiently formed on the surface of at least a part of the base material. Specifically, the efficiency of the graft polymerization of compound B is improved by the excluded volume effect and the gel effect of the polymer C contained in the solvent D. The excluded volume effect and the gel effect will be described below.
- FIG. 1 is a schematic diagram illustrating the excluded volume effect.
- the polymer C has a volume in the treatment liquid. Further, since the repulsive force acts on the polymers C in general, the proximity of the polymers C to each other is restricted. Therefore, as shown in FIG. 1, the region where the compound B can exist is narrower in the treatment liquid 1001 to which the polymer C is added, as compared with the treatment liquid 1000 to which the polymer C is not added. This is called the excluded volume effect. As a result, the apparent concentration of compound B and / or the consumption rate of compound B in the treatment liquid is increased, so that the graft polymerization efficiency of compound B is improved.
- FIG. 2 is a schematic diagram illustrating the gel effect.
- the entire treatment liquid has a high viscosity.
- the stopping reaction which is a bimolecular reaction between the polymers B. That is, when the polymers B having growth radicals react with each other, further polymerization at the terminal of the polymer B can be stopped, but if the treatment liquid has a high viscosity, the termination of this polymerization is reduced. This is called the gel effect. This increases the apparent rate of consumption of compound B.
- a graft chain having a length equal to or longer than the conventional one and / or a graft layer having a thickness equal to or thicker than the conventional one can be obtained from the polymer A at a concentration of compound B lower than the conventional one. It becomes possible to efficiently form the surface of the base material containing the above.
- the treatment liquid according to the embodiment of the present disclosure contains compound B, a polymer C, and a solvent D, and a graft obtained by graft-polymerizing the compound B on at least a part of the surface of the substrate containing the polymer A. It is a treatment liquid for forming a layer.
- the treatment liquid may contain the polymer C in addition to the compound B at the stage before the start of the graft polymerization.
- the amount of compound B used and the amount of waste can be reduced as compared with the prior art. That is, the production efficiency can be improved and the burden on the environment can be reduced.
- Polymer B is formed by the polymerization of compound B.
- compound B forms a graft layer by graft polymerization.
- the compound B may be one kind or a plurality of kinds.
- the compound B may be electrically neutral. This can reduce interactions within and / and between compound B.
- electrically neutral means that it does not have or has a group that ionizes into an ion in an aqueous solution having a pH (pH 6 to 8) near neutrality. It has a group that becomes a cation and a group that becomes an anion, which means that the total charge is substantially zero. As used herein, “substantially” means that the total charge is zero, or even if it is not zero, it is small enough not to adversely affect the effects of the present disclosure.
- Compound B may have a phosphorylcholine group. This allows the graft layer to maintain high biocompatibility and / and good lubrication for long periods of time.
- Compound B may further have a polymerization initiating group.
- compound B may be a polymerizable monomer having a phosphorylcholine group at one end and a polymerization initiating group graft-polymerizable with a substrate at one of the other ends.
- Compound B may have a polymerizable methacrylic acid unit as the polymerization initiating group. Thereby, the graft layer can be easily formed.
- Examples of the compound B having a phosphorylcholine group include 2-methacryloyloxyethylphosphorylcholine, 2-acryloyloxyethylphosphorylcholine, 4-methacryloyloxybutylphosphorylcholine, 6-methacryloyloxyhexylphosphorylcholine, ⁇ -methacryloyloxyethylenephosphorylcholine and the like.
- 2-methacryloyloxyethyl phosphorylcholine is also referred to as "MPC”.
- MPC polymer polymerized by MPC
- PMPC poly (MPC) or PMPC.
- MPC has a chemical structure shown in the following structural formula, and is a polymerizable monomer having a phosphorylcholine group and a polymerizable methacrylic acid unit.
- MPCs are easily polymerized by radical polymerization, high-molecular-weight homopolymers can be formed (Ishihara et al., Polymer Journal 22, p355 (1990)). Therefore, when the graft layer is formed as an aggregate of the polymer chains obtained by polymerizing the MPC, the graft bond between the MPC polymer chains and the surface of the base material can be performed under relatively gentle conditions. In addition, high density graft chains and / and graft layers can be formed to form large amounts of phosphorylcholine groups on the surface of the substrate.
- the graft layer may be formed not only as a homopolymer composed of a single polymerizable monomer having a phosphorylcholine group, but also as a copolymer composed of a polymerizable monomer having a phosphorylcholine group and, for example, another vinyl compound monomer. can. Thereby, depending on the type of other vinyl compound monomers used, functions such as improvement of mechanical strength can be added to the graft layer.
- examples of the compound B include polyethylene glycol dimethacrylate, a monomer having a betaine structure (methacryloxyethyl carboxybetaine, methacryloyloxyethyl sulfobetaine, and methacryloyloxyethylamide betaine).
- the concentration of compound B in the treatment liquid can be appropriately changed depending on the type of compound B, but may be, for example, 0.05 to 0.25 mol / L, or 0.10 to 0.25 mol / L. It may be 0.10 to 0.20 mol / L, and may be 0.10 to 0.20 mol / L.
- concentration of the compound B is within the above range, the production cost and the impact on the environment can be reduced, and a graft layer having a sufficient density and thickness can be formed, and the wettability and wear resistance of the surface of the graft layer can be reduced. Can improve sex.
- the polymer C brings about the excluded volume effect and the gel effect as described above.
- the polymer C is not particularly limited as long as it is a polymer that does not interfere with the graft polymerization of compound B.
- the polymer C may be an organic polymer or an inorganic polymer. From the viewpoint of solubility in the solvent D, the polymer C may be an organic polymer.
- the polymer C may be one type or a plurality of types.
- the polymer C may be electrically neutral. "Electrically neutral” is as described above. If the polymer C is electrically neutral, the interaction within and / and between the polymers C can be reduced, and the interaction between the polymer C and the compound B and / and the polymer B. Can also be reduced.
- the weight average molecular weight of the polymer C may be 10,000 or more, 10,000 to 1,000,000, or 100,000 to 1,000,000. With the above configuration, the exclusion volume effect of the polymer C in the treatment liquid is improved, and the efficiency of the graft polymerization of the compound B is improved.
- the weight average molecular weight can be measured, for example, by gel permeation chromatography.
- the polymer C may have a phosphorylcholine group.
- the monomer constituting the polymer C may be the same compound as the compound B.
- the polymer C may be, for example, poly (2-methacryloyloxyethyl phosphorylcholine).
- the polymer B and the polymer C may be different compounds that do not react with each other.
- the efficiency of the graft polymerization of the compound B can be improved.
- polymer C examples include polypolyethylene glycol methacrylate, polymers having various betaine groups, starch, sucrose, hyaluronic acid and the like, in addition to the polymer having a phosphorylcholine group.
- the concentration of the polymer C in the treatment liquid can be appropriately changed depending on the type of the polymer C, and may be, for example, 1 ⁇ mol / L or more, or 1 to 1000 ⁇ mol / L.
- concentration of the polymer C is within the above range, the exclusion volume effect of the polymer C in the treatment liquid can be improved, and the efficiency of the graft polymerization of the compound B can be improved. Further, even when the polymer B is used as the polymer C, the amount of the compound B discarded can be reduced as compared with the case where the polymer B is not used.
- the dissolved oxygen concentration in the treatment liquid before the start of graft polymerization may be 6.0 mg / L or less, or 0.2 mg / L or less.
- the inhibition of polymerization of compound B by the dissolved oxygen can be reduced.
- the solvent D is not particularly limited, and may be a hydrophilic solvent or a hydrophobic solvent. From the viewpoint of environmental load, it may be a hydrophilic solvent.
- the hydrophilic solvent include water, saline solution, sugar water, water / ethanol mixed solution and the like.
- the hydrophobic solvent include alcohol, acetone, hexane and the like.
- the solvent D may contain at least water.
- the solvent D may be a good solvent for at least one of the polymer B on which the compound B is polymerized and the polymer C.
- the solvent D may be a good solvent for both the polymer B and the polymer C.
- the term "good solvent” refers to a solvent in which the solubility of the target compound is relatively large as compared with the poor solvent described later. With the above configuration, a large amount of the polymer B and / or the polymer C can be dissolved in the solvent, so that the efficiency of the graft polymerization can be improved.
- the solvent D may be a good solvent for the compound B. If the solvent D is a good solvent for the compound B, the motility of the compound B in the solvent D can be improved, so that the efficiency of the graft polymerization of the compound B can be improved.
- a poor solvent can be used as the solvent.
- a good solvent of the polymer B can be used as described above.
- the treatment liquid may further contain an inorganic salt soluble in the solvent D. Thereby, the efficiency of the graft polymerization of compound B can be improved.
- a water-soluble inorganic salt may be used as the inorganic salt.
- the water-soluble inorganic salt include alkali metal salts and alkaline earth metal salts.
- the alkali metal salt include sodium salt, potassium salt, lithium salt, cesium salt and the like.
- the alkaline earth metal salt include magnesium salt, calcium salt, strontium salt, barium salt, radium salt and the like.
- the inorganic salt is classified according to the type of counter anion, a halide (for example, chloride, fluoride, bromide, iodide, etc.), a phosphate, a carbonate, a nitrate, a hydroxide and the like can be mentioned.
- the water-soluble inorganic salt is, for example, one or more selected from the group consisting of sodium chloride, potassium chloride, calcium chloride and magnesium chloride.
- the concentration of the inorganic salt in the treatment liquid may be, for example, 0.01 to 5.0 mol / L, 1.0 to 5.0 mol / L, or 1.0 to 3.0 mol / L. It may be L. At the above concentration, a graft layer having a sufficient graft density can be efficiently formed.
- the substrate is the target for forming the graft layer.
- the substrate may contain macromolecule A in at least a portion of its surface.
- the substrate may contain, for example, a functional compound such as an antioxidant, a cross-linking agent and / or a reinforcing material such as carbon fiber.
- Examples of the polymer A include polyolefins, aromatic polyetherketones and the like.
- the polymer A may be one type or a plurality of types.
- Examples of the polyolefin include polyethylene and the like.
- Examples of polyethylene include ultra-high molecular weight polyethylene (UltraHigh Molecular Weight Polyethylene, UHMWPE) from the viewpoint of excellent mechanical properties such as wear resistance, impact resistance, and deformation resistance.
- UHMWPE ultra-high molecular Weight Polyethylene
- examples of the aromatic polyetherketone include polyetheretherketone (PEEK) from the viewpoint of excellent mechanical properties such as impact resistance and deformation resistance.
- the polymer A may contain free radicals.
- free radical means a molecule having unpaired electrons and paramagnetism.
- the content of free radicals can be measured by electron spin resonance.
- the amount of free radicals may be 1.0 ⁇ 10 14 spins / g or more, 1.0 ⁇ 10 14 to 1.0 ⁇ 10 20 spins / g, or 1.0 ⁇ 10 15 It may be ⁇ 1.0 ⁇ 10 20 spins / g.
- the molecular weight of the polymer constituting the base material may be 1 million or more, 1 million to 7 million, or 3 million to 7 million. In particular, it may be 3 to 4 million.
- the molecular weight of the polymer constituting the base material may be 50,000 or more, 80,000 to 500,000, or 80,000 to 200,000. There may be.
- the contacting step is a step of bringing the base material containing the polymer A into contact with the treatment liquid containing the compound B and the polymer C in the solvent D.
- at least a part of the base material may be brought into contact with the treatment liquid.
- a part of the surface of the base material on which the polymer A is present may be brought into contact with the treatment liquid, or the entire base material may be brought into contact with the treatment liquid.
- the method of bringing the base material into contact with the treatment liquid is not particularly limited, and any method can be used. From the viewpoint of efficiently forming the graft layer, a method of immersing the base material in the treatment liquid may be used.
- the time for contacting the base material with the treatment liquid is not particularly limited, but the contact may be performed for 5 minutes or more from the viewpoint of performing the polymerization step described later.
- the polymerization step is a step of graft-polymerizing the compound B to the polymer A constituting at least a part of the surface of the base material during the contact step.
- the polymerization step can be performed at the same time as the contact step.
- the method of graft polymerization is not particularly limited, and may be, for example, photo-initiated graft polymerization or heat-initiated graft polymerization.
- the polymer B on which compound B is polymerized can be stably immobilized on the surface of the substrate. Further, according to the photo-initiated graft polymerization, the density of the graft layer can be increased by forming the polymer B on the surface of the substrate at a high density.
- the photo-initiated graft polymerization may be initiated by visible light or by ultraviolet light.
- the compound B in the vicinity of the surface is polymerized to form the polymer B.
- the produced polymer B is covalently bonded to the surface of the substrate.
- a graft layer covering the surface of the substrate as a whole is formed.
- the base material may be heated.
- Photoinitiated graft polymerization can be controlled by heating the substrate and the treatment liquid in contact with the substrate.
- a photopolymerization initiator may be contained on the surface of the base material.
- a photopolymerization initiator may be applied to the surface of the base material before the base material is brought into contact with the treatment liquid.
- the photopolymerization initiator radical generated by the irradiation with ultraviolet rays forms a polymerization initiation point on the surface of the substrate.
- Compound B reacts with the polymerization initiation point to initiate graft polymerization, resulting in polymer B.
- the wavelength of the ultraviolet rays to be irradiated is, for example, 300 to 400 nm.
- the ultraviolet irradiation light source for example, a high-pressure mercury lamp (UVL-400HA manufactured by Riko Kagaku Sangyo Co., Ltd.), an LED (MeV365-P601JMM manufactured by YEV Co., Ltd.) and the like can be used.
- the irradiation time of ultraviolet rays may be 11 to 90 minutes or 23 to 90 minutes.
- the heating temperature and heating time of the thermal initiation graft polymerization are not particularly limited, but the heating temperature may be equal to or lower than the melting point of the polymer A and / or the polymer B and / or the polymer C, and may be equal to or lower than the boiling point of the solvent D. May be good.
- the heating temperature may be, for example, 25 to 150 ° C., and the heating time may be, for example, 10 to 180 minutes.
- the graft polymerization may be started by irradiating with gamma rays.
- the irradiation time of gamma rays is not particularly limited, but may be, for example, 5 to 120 minutes.
- the treatment liquid may be removed by washing. Further, sterilization treatment with gamma ray irradiation, ethylene oxide gas or the like may be further performed.
- the method for producing a complex is a method for producing a complex including a base material and a graft layer covering at least a part of the surface of the base material.
- the method for producing the complex includes a step of forming a graft layer in which compound B is graft-polymerized on at least a part of the surface of the substrate containing the polymer A by the above-mentioned method for forming a graft layer.
- the production method may use a commercially available product as a base material, or may include a base material forming step before the step of forming the graft layer.
- the substrate can be obtained, for example, by charging a powdery, granular or pelletized polymer A into a mold and then compression molding, extrusion molding or injection molding.
- the polymer A include the above-mentioned UHMWPE and PEEK.
- UHMWPE and PEEK are thermoplastic resins, but their fluidity is low even at the melting temperature or higher. Therefore, solid UHMWPE or PEEK may be put into a mold and molded under high heat and high pressure conditions.
- an antioxidant; a cross-linking agent; a reinforcing material such as carbon fiber may be put into the mold.
- the method for producing a composite according to an embodiment of the present disclosure is crosslinked in the molecule of the polymer A before the step of forming the graft layer, for example, between the step of forming the substrate and the step of forming the graft layer. It may include a cross-linking step that results in the structure. As a result, a base material having further improved mechanical properties such as wear resistance can be obtained.
- the cross-linking step may include a step of irradiating the base material with high energy rays. This process is also referred to as a high energy ray irradiation process. Free radicals are generated by irradiating the base material with high energy rays.
- the polymer A can be bonded between the molecular chains to obtain the polymer A having a crosslinked structure.
- mechanical properties such as wear resistance and impact resistance are improved.
- the cross-linking reaction can be performed by adding a cross-linking agent, but it tends to be difficult to completely remove the unreacted cross-linking agent. Therefore, the cross-linking reaction by high-energy beam irradiation may be used in consideration of the influence of the unreacted cross-linking agent on the living body.
- high energy rays examples include X-rays, gamma rays and electron beams.
- the irradiation dose of the high energy ray may be, for example, 25 to 200 kGy or 50 to 150 kGy.
- the high energy radiation source for example, a radiation device using Co (cobalt) 60 as a radiation source, an accelerator that emits an electron beam, a device that irradiates X-rays, or the like can be used as a gamma ray source.
- the cross-linking step may further include a heat treatment step after the high energy ray irradiation step.
- the heat treatment step the free radicals generated by the high energy beam irradiation step are more efficiently consumed in the cross-linking reaction to promote intramolecular cross-linking.
- the temperature range of the heat treatment may be 110 to 130 ° C.
- the heat treatment treatment time may be 2 to 12 hours.
- the complex produced by the manufacturing method can be used, for example, as a member for medical equipment, a member for industrial equipment, or the like.
- the medical device member include artificial joint members, artificial blood vessels, artificial hearts, various stents, and the like.
- the artificial joint to which the artificial joint member is applied is not particularly limited, and examples thereof include an artificial hip joint, an artificial knee joint, an artificial ankle joint, an artificial shoulder joint, an artificial elbow joint, an artificial finger joint, and an artificial intervertebral disc.
- the hip prosthesis may include a head and acetabulum.
- the artificial joint member according to one embodiment of the present disclosure can be applied to the head, the acetabulum, or both.
- the other is a metal such as stainless steel or cobalt-chromium alloy; ceramics such as alumina or zirconia; and a polymer such as UHMWPE or PEEK.
- the head and acetabulum may be made of different materials.
- the head may be made of a polymer, ceramic or metal material
- the acetabular substrate may be made of, for example, a polymer material.
- FIG. 3 is a schematic view of the artificial hip joint 1 according to the embodiment of the present disclosure.
- FIG. 4 is a schematic view of the acetabular cup 10 according to the embodiment of the present disclosure.
- the artificial hip joint 1 is composed of a acetabular cup 10 fixed to the acetabulum 94 of the hip bone 93 and a femur stem 20 fixed to the proximal end of the femur 91.
- the acetabular cup 10 has a cup base material 12 having a substantially hemispherical acetabular fixation surface 14 and a substantially hemispherically recessed sliding surface 16, and a graft layer 30 covering the sliding surface 16. ing.
- the head 22 of the femoral stem 20 is fitted into the recess 161 in which the graft layer 30 of the acetabular cup 10 is formed and slid, thereby functioning as a hip joint.
- the acetabular fixation surface 14 is an outer surface arranged on the side close to the acetabulum 94.
- the sliding surface 16 is also an inner surface or a contact surface that contacts the head 22.
- the sliding surface 16 of the cup base material 12 is covered with the graft layer 30.
- the graft layer 30 is obtained by graft-polymerizing the polymer B on which the compound B is polymerized onto the sliding surface 16.
- the graft layer 30 may be arranged only on the acetabular cup 10 or on both the acetabular cup 10 and the head 22.
- the graft layer 30 has a high affinity with the lubricating liquid in the joint, similar to the structure of the biological membrane, and can hold the lubricating liquid inside the membrane. Further, the graft layer 30 has a phosphoric acid group at a high density. Therefore, the acetabular cup 10 exhibits excellent wear resistance.
- Example 1 2-methacryloyloxyethyl phosphorylcholine (MPC) monomer was used as the compound B, polyMPC (PMPC) was used as the polymer C, and pure water was used as the solvent D.
- the weight average molecular weight of the polymer C was 200 to 1,000,000.
- PMPC, NaCl and MPC were dissolved in pure water to prepare a treatment liquid.
- the PMPC concentration in the treatment liquid was 10 ⁇ mol / L
- the NaCl concentration was 2.5 mol / L
- the MPC concentration was 0.05 mol / L.
- a square lumber (cross section: 10 mm ⁇ 3 mm, length: 50 mm) made of ultra-high molecular weight polyethylene having a molecular weight of 3 to 4 million and a density of 0.93 g / cm 3 was used as a base material.
- the square lumber was immersed in the prepared treatment liquid, and then irradiated with ultraviolet rays for 90 minutes. After the ultraviolet irradiation was completed, the square lumber was pulled up and thoroughly washed with pure water and ethanol to obtain a test piece having a PMPC graft layer formed on the surface of the substrate.
- each treatment liquid in which the MPC concentration was changed to 0.08 mol / L, 0.1 mol / L, 0.15 mol / L, 0.2 mol / L, 0.25 mol / L, and 0.5 mol / L was used.
- a test piece was prepared by the same method as above.
- Comparative Example 1 A test piece was prepared in the same manner as in Example 1 except that the polymer C was not added to the treatment liquid. In addition, in Comparative Example 1, a test piece using a treatment liquid to which neither compound B nor polymer C was added was prepared.
- FIG. 5 is a graph showing the relationship between the MPC concentration in the treatment liquid and the static contact angle of water in Example 1 and Comparative Example 1.
- black circles are the results of the test piece of Example 1 prepared by adding polymer C
- white circles are the results without adding polymer C. It means the result of the prepared test piece of Comparative Example 1.
- the contact angle of the test piece having an MPC concentration of 0.08 to 0.25 mol / L in the treatment liquid showed a low value of 45 ° or less.
- the contact angle of the test piece of the example in which the MPC concentration in the treatment liquid was 0.1 to 0.2 mol / L showed a particularly low value.
- FIG. 6 is a graph showing the relationship between the MPC concentration in the treatment liquid and the thickness of the graft layer in Example 1 and Comparative Example 1.
- the meanings of the black circles and the white circles in FIG. 6 are the same as those in FIG. From FIG. 6, it was found that in Example 1, a graft layer having a thickness equal to or thicker than that of the prior art can be formed even if the concentration of MPC in the treatment liquid is low.
- the MPC concentration in the treatment liquid is 0.08 to 0.25 mol / L
- the thickness of the graft layer is 50 to 250 nm, and the graft is more than the test piece of Comparative Example 1 to which the polymer C is not added. It was shown that the thickness of the layer was large.
- the invention according to the present disclosure can be used as a method for forming a graft layer.
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Abstract
Description
本開示の一実施形態に係るグラフト層の形成方法は、化合物Bおよび高分子Cを溶媒D中に含む処理液に、高分子Aを含む基材を接触させる接触工程を含む。前記接触工程中には、前記基材の表面の少なくとも一部を構成する前記高分子Aに対して、前記化合物Bをグラフト重合する重合工程が含まれる。
本開示の一実施形態に係る処理液は、化合物Bと、高分子Cと、溶媒Dとを含み、高分子Aを含む基材の表面の少なくとも一部に、前記化合物Bがグラフト重合したグラフト層を形成するための処理液である。当該処理液は、グラフト重合を開始する前の段階で、化合物Bに加えて高分子Cが含まれ得る。
基材は、グラフト層を形成する対象となる。基材は、その表面の少なくとも一部に高分子Aを含み得る。基材は、例えば抗酸化剤、架橋剤等の機能性化合物および/または炭素繊維等の強化材を含んでいてもよい。
分子量=5.37×104×(固有粘度)1.49 ・・・(1)
また、基材を構成する高分子の密度は、耐衝撃性、耐変形性等の機械的特性の観点から、ポリオレフィンを含む基材の場合、0.927~0.944g/cm3であってもよい。また、芳香族ポリエーテルケトンを含む基材の場合、1.20~1.55g/cm3であってもよい。
接触工程は、化合物Bおよび高分子Cを溶媒D中に含む処理液に、高分子Aを含む基材を接触させる工程である。接触工程では、基材の少なくとも一部を処理液と接触させればよい。例えば高分子Aが存在する基材の表面の一部を処理液と接触させてもよく、基材全体を処理液と接触させてもよい。
重合工程は、前記接触工程中に、前記基材の表面の少なくとも一部を構成する前記高分子Aに対して、前記化合物Bをグラフト重合する工程である。重合工程は接触工程と同時に行われ得る。グラフト重合の方式は特に限定されず、例えば、光開始グラフト重合であってもよく、熱開始グラフト重合であってもよい。
本開示の一実施形態に係る複合体の製造方法は、基材と、当該基材の表面の少なくとも一部を被覆するグラフト層とを含む複合体の製造方法である。当該複合体の製造方法は、上述のグラフト層の形成方法によって、高分子Aを含む基材の表面の少なくとも一部に、化合物Bがグラフト重合したグラフト層を形成する工程を含む。〔1.グラフト層の形成方法〕で既に説明した事項については以下では説明を省略する。
前記製造方法は、基材として市販品を用いてもよいし、グラフト層を形成する工程の前に基材形成工程を含んでいてもよい。基材は、例えば、粉末状、粒状またはペレット状の高分子Aを金型に投入し、次いで圧縮成型、押し出し成型または射出成型することで得られる。高分子Aとしては、上述のUHMWPEおよびPEEKが挙げられる。UHMWPEおよびPEEKは、熱可塑性樹脂であるが、溶融温度以上でも流動性が低い。そのため、固体状のUHMWPEまたはPEEKを金型に投入して高熱高圧条件下で成型してもよい。高分子Aとともに抗酸化剤;架橋剤;炭素繊維等の強化材を金型に投入してもよい。
本開示の一実施形態に係る複合体の製造方法は、グラフト層を形成する工程の前、例えば、基材形成工程とグラフト層を形成する工程との間に、高分子Aの分子内に架橋構造を生じさせる架橋工程を含んでいてもよい。これにより、耐摩耗性などの機械的特性がさらに向上した基材が得られる。
前記製造方法により製造される複合体は、例えば、医療機器用部材、産業用機器部材等として使用できる。前記医療機器用部材としては例えば、人工関節用部材、人工血管、人工心臓、各種ステント等が挙げられる。
化合物Bとして2-メタクリロイルオキシエチルホスホリルコリン(MPC)モノマー、高分子CとしてポリMPC(PMPC)、溶媒Dとして純水を用いた。高分子Cの重量平均分子量は20~100万であった。PMPC、NaCl、MPCを純水に溶解させ、処理液を作製した。処理液中のPMPC濃度を10μmol/L、NaCl濃度を2.5mol/L、MPC濃度を0.05mol/Lとした。また、高分子Aとして、分子量300~400万、密度0.93g/cm3の超高分子量ポリエチレンからなる角材(断面:10mm×3mm、長さ:50mm)を基材として用いた。作製した処理液に角材を浸漬し、次いで紫外線を90分間照射した。紫外線照射が終了後、角材を引き上げて、純水およびエタノールで十分に洗浄することにより、基材表面にPMPCのグラフト層が形成された試験片を得た。
処理液に高分子Cを添加しないこと以外は実施例1と同様にして試験片を作製した。加えて比較例1では、化合物Bおよび高分子Cのいずれも添加していない処理液を使用した試験片も作製した。
各試験片の親水性を、各試験片のグラフト層が形成された面に純水を滴下した際の接触角(水の静的接触角)を測定することによって評価した。水の静的接触角は、表面接触角測定装置(協和界面科学社製 DM300)を用い、液滴法により評価した。具体的には、ISO15989規格に準拠し、液滴量1μLの純水を試験片表面に滴下して60秒後に接触角を測定した。
各試験片について、試験片をエポキシ樹脂に包埋し、次いで四塩化ルテニウムを用いて染色した。その後、ウルトラミクロトームを用いて試験片から超薄切片を切り出した。加速電圧100kVとする透過型電子顕微鏡(TEM)を用いて、超薄切片の切断面の電子顕微鏡画像を得た。得られた電子顕微鏡画像の1画像につき、切断面における膜厚を10点測定し、その平均値を算出してグラフト層の厚さとした。
図5は、実施例1および比較例1における処理液中のMPC濃度と水の静的接触角との関係を示すグラフである。図5中、黒丸(高分子C(+))は高分子Cを添加して作製した実施例1の試験片の結果を、白丸(高分子C(-))は高分子Cを添加しないで作製した比較例1の試験片の結果を意味する。図5より、実施例1では、処理液中の化合物Bが低濃度であっても、親水性が高いグラフト層を形成可能であることがわかった。特に処理液中のMPC濃度が0.08~0.25mol/Lの試験片の接触角が45°以下の低値を示した。また、処理液中のMPC濃度が0.1~0.2mol/Lである実施例の試験片の接触角が特に低値を示した。
10 寛骨臼カップ(人工関節用部材)
12 カップ基材(基材)
30 グラフト層
Claims (15)
- 化合物Bおよび高分子Cを溶媒D中に含む処理液に、高分子Aを含む基材を接触させる接触工程と、
前記接触工程中に、前記基材の表面の少なくとも一部を構成する前記高分子Aに対して、前記化合物Bをグラフト重合する重合工程と、を含む、グラフト層の形成方法。 - 前記高分子Cの重量平均分子量が1万以上である、請求項1に記載のグラフト層の形成方法。
- 前記溶媒Dが、前記化合物Bが重合した高分子B、および前記高分子Cの少なくとも一方に対する良溶媒である、請求項1または2に記載のグラフト層の形成方法。
- 前記処理液が、溶媒Dに可溶な無機塩をさらに含む、請求項1~3のいずれか1項に記載のグラフト層の形成方法。
- 前記化合物Bが、ホスホリルコリン基を有する、請求項1~4のいずれか1項に記載のグラフト層の形成方法。
- 前記化合物Bが、重合性のメタクリル酸ユニットを有する、請求項1~5のいずれか1項に記載のグラフト層の形成方法。
- 前記高分子Aが、ポリオレフィンまたは芳香族ポリエーテルケトンである、請求項1~6のいずれか1項に記載のグラフト層の形成方法。
- 請求項1~7のいずれか1項に記載のグラフト層の形成方法によって、高分子Aを含む基材の表面の少なくとも一部に、化合物Bがグラフト重合したグラフト層を形成する工程を含む、基材と、当該基材の表面の少なくとも一部を被覆するグラフト層とを含む複合体の製造方法。
- 前記複合体は、医療機器用部材である、請求項8に記載の複合体の製造方法。
- 前記医療機器用部材は、人工関節用部材である、請求項9に記載の複合体の製造方法。
- 化合物Bおよび高分子Cを溶媒D中に含み、
高分子Aを含む基材の表面の少なくとも一部に、前記化合物Bがグラフト重合したグラフト層を形成するための処理液。 - 前記高分子Cの重量平均分子量が1万以上である、請求項11に記載の処理液。
- 前記溶媒Dが、前記化合物Bが重合した高分子B、および前記高分子Cの少なくとも一方に対する良溶媒である、請求項11または12に記載の処理液。
- 前記溶媒Dに可溶な無機塩をさらに含む、請求項11~13のいずれか1項に記載の処理液。
- 前記化合物Bが、ホスホリルコリン基を有する、請求項11~14のいずれか1項に記載の処理液。
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