Peroxide cross-linking and high temperature melting
AssigneeThe General Hospital Corporation
InventorsOrhun K. Muratoglu, Ebru Oral
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Abstract
Methods of making oxidation and wear resistant polymeric materials using peroxide cross-linking and high temperature melting process are disclosed. A multiple step procedure for enabling the manufacturing of such material without size limitations is also disclosed.
Claims132
A method of making a consolidated polymeric material comprising:
- blending the polymeric material with one or more additives;
- pre-molding the blended polymeric material into a partially consolidated form;
- heating the pre-molded polymeric material to a temperature above the melting temperature of the blended polymeric material for a period of time;
- cooling the pre-molded blended polymeric material;
- and
- completely consolidating the pre-molded, heat treated blended polymeric material.
A method of making a consolidated polymeric material comprising:
- blending the polymeric material with one or more additives;
- pre-molding the blended polymeric material into a partially consolidated form under hydrostatic pressure below 200° C., followed by completely consolidating by heating the pre-molded polymeric material to a temperature above 200° C. for a period of time under hydrostatic pressure;
- and
- cooling the completely consolidated premolded blended polymeric material.
A method of making a consolidated polymeric material comprising:
- blending the polymeric material with one or more additives;
- consolidating the polymeric material blend under hydrostatic pressure above 200° C.;
- and
- cooling the completely consolidated blended polymeric material.
A method of making a cross-linked consolidated polymeric material comprising:
- blending the polymeric material with one or more additives;
- pre-molding the blended polymeric material into a partially consolidated form;
- heating the pre-molded polymeric material to a temperature above the melting temperature of the blended polymeric material for a period of time;
- cooling the pre-molded blended polymeric material;
- completely consolidating the pre-molded, heat treated blended polymeric material;
- and
- irradiating the consolidated polymeric material.
A method of making a medical implant comprising:
- blending a polymeric material with one or more additives;
- pre-molding the blended polymeric material into a partially consolidated form;
- heating the pre-molded blended polymeric material to a temperature above the melting temperature of the blended polymeric material for a period of time;
- cooling the pre-molded blended polymeric material;
- completely consolidating the pre-molded, heat treated blended polymeric material;
- machining the consolidated polymeric material into implant shape;
- and
- irradiating the medical implant.
A method of making a cross-linked consolidated polymeric material comprising blending the polymeric material with one or more additives, pre-molding the blended polymeric material into a partially consolidated form, heating the pre-molded polymeric material to a temperature above the melting temperature of the blended polymeric material for a period of time, cooling the pre-molded blended polymeric material, completely consolidating the pre-molded, heat treated blended polymeric material, irradiating the consolidated polymeric material and heating the irradiated consolidated polymeric material.
A method of making a medical implant comprising:
- blending a polymeric material with one or more additives;
- pre-molding the blended polymeric material into a partially consolidated form;
- heating the pre-molded blended polymeric material to a temperature above the melting temperature of the blended polymeric material for a period of time;
- cooling the pre-molded blended polymeric material;
- completely consolidating the pre-molded, heat treated blended polymeric material;
- machining the consolidated polymeric material into a medical implant shape:
- and
- irradiating the medical implant.
A method of making a medical implant comprising:
- blending a polymeric material with one or more additives;
- pre-molding the blended polymeric material into a partially consolidated form;
- heating the pre-molded blended polymeric material to a temperature above the melting temperature of the blended polymeric material for a period of time;
- cooling the pre-molded blended polymeric material;
- completely consolidating the pre-molded, heat treated blended polymeric material;
- irradiating the consolidated polymeric material;
- heating the irradiated consolidated polymeric material;
- and
- cooling, machining the irradiated consolidated material into implant shape.
A method of making a medical implant comprising:
- blending a polymeric material with one or more additives;
- pre-molding the blended polymeric material into a partially consolidated form;
- heating the pre-molded blended polymeric material to a temperature above the melting temperature of the blended polymeric material for a period of time;
- cooling the pre-molded blended polymeric material;
- and
- completely consolidating the pre-molded, heat treated blended polymeric material into implant shape by direct compression molding.
A method of making a interlocked hybrid medical implant comprising:
- blending a polymeric material with one or more additives;
- pre-molding the blended polymeric material into a partially consolidated form;
- heating the pre-molded blended polymeric material to a temperature above the melting temperature of the blended polymeric material for a period of time;
- cooling the pre-molded blended polymeric material;
- and
- completely consolidating the pre-molded, heat treated blended polymeric material into implant shape by direct compression molding onto a second material.
A method of making a cross-linked consolidated polymeric material comprising:
- blending a polymeric material with one or more additives;
- pre-molding the blended polymeric material into a partially consolidated form;
- heating the pre-molded polymeric material to a temperature above the melting temperature of the polymeric material for a period of time;
- cooling the pre-molded polymeric material;
- completely consolidating the pre-molded, heat treated polymeric material;
- irradiating the consolidated polymeric material;
- machining the irradiated consolidated polymeric material;
- diffusing the implant preform with one or more additives;
- and
- heating and subsequently cooling the diffused implant preform.
A method of making a medical implant comprising:
- blending a polymeric material with one or more additives;
- pre-molding the blended polymeric material into a partially consolidated form;
- heating the pre-molded polymeric material to a temperature above the melting temperature of the polymeric material for a period of time;
- cooling the pre-molded polymeric material;
- completely consolidating the pre-molded, heat treated polymeric material;
- irradiating the consolidated polymeric material;
- machining the irradiated consolidated polymeric material into a medical implant perform;
- diffusing the implant preform with one or more additives;
- and
- heating the diffused implant preform and subsequently cooling and machining into implant shape.
A method of making a consolidated polymeric material comprising:
- blending a polymeric material with one or more additives;
- pre-molding the blended polymeric material into partially consolidated form;
- heating the pre-molded polymeric material to a temperature above its melting temperature of the polymeric material for a period of time;
- cooling the pre-molded polymeric material;
- layering the pre-molded polymeric material with a layer of a cross-link agent-blended pre-molded or resin polymeric material;
- and
- completely consolidating the layered material.
A method of making a medical implant comprising:
- blending a polymeric material with one or more additives;
- pre-molding the blended polymeric material into partially consolidated form;
- heating the pre-molded polymeric material to a temperature above its melting temperature of the polymeric material for a period of time;
- cooling the pre-molded polymeric material;
- layering the pre-molded polymeric material with more than one layer of cross-link agent-blended pre-molded or resin polymeric material;
- and
- completely consolidating the layered material.
A method of making a medical implant comprising:
- blending a polymeric material with one or more additives;
- pre-molding the blended polymeric material into partially consolidated form;
- heating the pre-molded polymeric material to a temperature above its melting temperature of the polymeric material for a period of time;
- cooling the pre-molded polymeric material;
- layering the pre-molded polymeric material with a layer of a cross-link agent-blended pre-molded or resin polymeric material;
- and
- completely consolidating the layered material.
The method according to any of claim 1-19 or 21-61, wherein the polymeric material is irradiated after the complete consolidation step.
The method according to any of claim 4-8, 11, 12, 20, 22, 45-50 or 60-61, wherein the irradiated polymeric material is further heated below the melting point of the irradiated polymeric material.
The method according to any of claim 1-22 or 24-61, wherein the polymeric material is heated below or above the melting point of the polymeric material.
The method according to any of claim 1-23 or 25-61, wherein the complete consolidation step is carried out by compression molding, direct compression molding, uniaxial compression, or hot isostatic pressing.
The method according to any of claim 1-24 or 16-61, wherein the polymeric material is blended with one or more antioxidants.
The method according to any of claim 1-25 or 27-61, wherein the polymeric material is blended with vitamin E.
The method according to any of claim 1-26 or 28-61, wherein the polymeric material is chosen from high-density-polyethylene, low-density-polyethylene, linear-low-density-polyethylene, ultra-high molecular weight polyethylene (UHMWPE), copolymers or mixtures thereof.
The method according to any of claim 1, 2, 4-15 or 29-40, wherein the pre-molding is done by compression.
The method according to any of claim 1, 2, 4-15, 28 or 30-40, wherein the pre-molding is done by isostatic pressure or hydrostatic pressure.
The method according to any of claim 1, 2, 4-15, 28, 29 or 31-40, wherein the pre-molding is done at a temperature between room temperature and the peak melting temperature of the polymeric material.
The method according to any of claim, 1, 2, 4-15, 28-30 or 32-40, wherein the pre-molding is done at a temperature close to the peak melting temperature of the polymeric material.
The method according to any of claim 1, 2, 4-15, 28, 29, 31 or 33-40, wherein the pre-molding is done at a temperature above the peak melting temperature of the polymeric material.
The method according to any of claim 1, 2, 4-15, 28-32 or 34-40, wherein the pre-molding is done at below the ambient pressure.
The method according to any of claim 1, 2, 4-15, 28-33 or 35-40, wherein the pre-molding is done under vacuum.
The method according to any of claim 1, 2, 4-15, 28-34 or 36-40, wherein the pre-molding is done under about 1, 2, 3, 4, 5 MPa or more of uniaxial or hydrostatic pressure.
The method according to any of claim 1, 2, 4-15, 28-35 or 37-40, wherein the heat treatment after pre-molding is done at a temperature above 200° C.
The method according to any of claim 1, 2, 4-15, 28-37 or 39-40, wherein the heat treatment after pre-molding is done for at least 1 hour up to 1 week.
The method according to any of claim 1-40 or 42-61, wherein the complete consolidation step is done by compression.
The method according to any of claim 1-41 or 43-61, wherein the complete consolidation step is done by applying isostatic or hydrostatic pressure.
The method according to any of claim 1-42 or 44-61, wherein the complete consolidation is done above the peak melting temperature of the polymeric material and a pressure from 0.1 to 1000 MPa.
The method according to any of claim 1-43 or 45-61, wherein the complete consolidation is done at a temperature between 170 and 230° C. and a pressure between 10 and 25 MPa.
The method according to any of claim 4-8, 11, 12, 20-22 or 46-50 or 58-61, wherein the irradiation is an electron beam irradiation.
The method according to any of claim 4-8, 11, 12 or 20-22, 45, 47-50 or 58-61, wherein the irradiation is a gamma irradiation.
The method according to any of claim 4-8, 11, 12, 20-22, 45, 46, 48-50 or 58-61, wherein the irradiation is performed at about room temperature.
The method according to any of claim 4-8, 11, 12, 20-22, 45-47, 49, 50 or 58-61, wherein the irradiation is performed at an elevated temperature below the melting point of the polymeric material.
The method according to any of claim 4-8, 11, 12, 20-22, 45-48, 50 or 58-61, wherein the irradiation is performed at an elevated temperature close to the peak melting temperature of the polymeric material.
The method according to any of claim 1-51 or 53-62, wherein the final polymeric material is machined into an implant.
A method according to any of claim 4-8, 11, 12, 20-22, 45-50 or 60-61, wherein the heating after irradiation is done below the peak melting temperature of the polymeric material.
A method according to any of claim 4-8, 11, 12, 20-22, 45-50 or 60-61, wherein the heating after irradiation is done above the peak melting temperature of the polymeric material.
The method according to any of claims wherein the cooling step is optional.
A method of making a cross-linked polymeric material, the method comprising:
- a. blending a polymeric material with one or more additive(s) at least one of which is an antioxidant and at least one of which is a cross-linking agent;
- b. consolidating the blended polymeric material;
- c. heating the consolidated polymeric material to a temperature below or above its melting temperature and maintaining for a period of time;
- d. heating the consolidated polymeric material to another temperature below or above its melting temperature and maintaining for a period of time;
- and
- e. cooling the heated consolidated polymeric material.
A method of making a cross-linked polymeric material, the method comprising:
- a. blending a polymeric material with one or more additive(s) at least one of which is an antioxidant and at least one of which is a cross-linking agent;
- b. heating the consolidated polymeric material to a temperature below or above its melting temperature and maintaining for a period of time;
- c. heating the consolidated polymeric material to another temperature below or above its melting temperature and maintaining for a period of time;
- d. cooling the heated consolidated polymeric material to a temperature above the melting temperature and maintaining for a period of time;
- e. cooling the heated consolidated polymeric material to another temperature below the melting temperature and maintaining for a period of time;
- and
- f. further cooling the heated consolidated polymeric material.
A method of making a cross-linked polymeric material, the method comprising:
- a. blending a polymeric material with one or more additive(s) at least one of which is an antioxidant and at least one of which is a carbon-carbon initiator;
- and
- b. consolidating the blended polymeric material.
A method of making a cross-linked polymeric material, the method comprising:
- a. blending a polymeric material with one or more additive(s) at least one of which is an antioxidant and at least one of which is a cross-linking agent;
- b. consolidating the blended polymeric material;
- c. heating the consolidated polymeric material to a temperature to between about 200° C. and about 290° C.;
- d. maintaining the consolidated polymeric material between about 200° C. and about 290° C. for at least 4 hours;
- e. heating the consolidated polymeric material to a temperature between about 290° C. and 350° C.;
- f. maintaining the consolidated polymeric material between about 290° C. and 350° C. for at least 5 hours but no more than 30 hours;
- g. cooling the heated consolidated polymeric material to a temperature between about 135° C. and about 180° C.;
- h. maintaining the consolidated polymeric material between about 135° C. and about 180° C.;
- and
- i. cooling the consolidated polymeric material to between about room temperature and 60° C.
A method of making a cross-linked polymeric material, the method comprising:
- a. blending a polymeric material with one or more additive(s) at least one of which is an antioxidant and at least one of which is a cross-linking agent;
- b. consolidating the blended polymeric material;
- c. heating the consolidated polymeric material;
- d. extracting byproducts from the consolidated polymeric material;
- and
- e. cooling the extracted consolidated polymeric material.
A method of making a cross-linked polymeric material, the method comprising:
- a. blending a polymeric material with one or more additive(s) at least one of which is an antioxidant and at least one of which is a cross-linking agent;
- b. consolidating the blended polymeric material;
- c. heating the consolidated polymeric material;
- d. cooling the consolidated polymeric material;
- and
- e. extracting byproducts from the consolidated polymeric material.
A method of making a cross-linked polymeric material, the method comprising:
- a. blending a polymeric material with one or more additive(s) at least one of which is an antioxidant;
- b. partially consolidating the blended polymeric material;
- c. high temperature melting the partially consolidated, blended polymeric material;
- d. consolidating the high temperature melted, partially consolidated, blended polymeric material;
- and
- e. irradiating the consolidated, blended polymeric material.
A method of making a cross-linked polymeric material, the method comprising:
- a. blending a polymeric material with one or more additive(s) at least one of which is an antioxidant;
- b. consolidating the blended polymeric material;
- c. high temperature melting the consolidated, blended polymeric material;
- d. consolidating the high temperature melted, partially consolidated, blended polymeric material;
- and
- e. irradiating the consolidated, blended polymeric material.
A method of making a cross-linked polymeric material, the method comprising;
- a. blending a first polymeric material with one or more additive(s) at least one of which is an antioxidant;
- b. partially consolidating the first blended polymeric material;
- c. high temperature melting the partially consolidated, blended polymeric material;
- d. blending a second polymeric material with one or more additive(s) at least one of which is an antioxidant and at least one of which is a cross-linking agent;
- and
- e. layering the partially consolidated, blended polymeric material and the second blended polymeric material and consolidating the layers, thereby forming a layered cross-linked polymeric material.
A method of making a cross-linked polymeric material, the method comprising:
- a. blending a first polymeric material with one or more additive(s) at least one of which is an antioxidant;
- b. partially consolidating the first blended polymeric material;
- c. blending a second polymeric material with one or more additive(s) at least one of which is an antioxidant and at least one of which is a cross-linking agent;
- and
- d. layering the partially consolidated, blended polymeric material and the second blended polymeric material and consolidating the layers, thereby forming a layered cross-linked polymeric material.
A method of making a cross-linked polymeric material, the method comprising:
- a. blending a first polymeric material with one or more additive(s) at least one of which is an antioxidant;
- b. bending a second polymeric material with one or more additive(s) at least one of which is an antioxidant and at least one of which is a cross-linking agent;
- and
- c. layering the first blended polymeric material and the second blended polymeric material and consolidating the layers, thereby forming a layered cross-linked polymeric material.
A method of making a cross-linked polymeric material, the method comprising:
- a. blending a first polymeric material with one or more additive(s) at least one of which is an antioxidant;
- b. partially consolidating the first blended polymeric material;
- c. blending a second polymeric material with one or more additive(s) at least one of which is an antioxidant and at least one of which is a cross-linking agent;
- d. Partially consolidating the second blended polymeric material;
- and
- e. layering the first and second partially consolidated, blended polymeric materials and consolidating the layers, thereby forming a layered cross-linked polymeric material.
A method of making an interlocked hybrid material, the method comprising:
- a. blending a first polymeric material with one or more additive(s) at least one of which is an antioxidant;
- b. partially consolidating the first blended polymeric material;
- c. blending a second polymeric material with one or more additive(s) at least one of which is an antioxidant and at least one of which is a cross-linking agent;
- and
- d. layering the partially consolidated, blended polymeric material and the second blended polymeric material and a third material consolidating the layers, thereby forming an interlocked, hybrid material.
Dependencies are inferred from the claim text.