Abstract Composite materials formed from bone bioactive glass or ceramic fibers and structural fibers are disclosed. In preferred embodiments, a braid or mesh of interwoven bone bioactive glass or ceramic fibers and structural fibers is impregnated with a polymeric material to provide a composite of suitable biocompatibility and structural integrity. Most preferably, the mesh or braid is designed so that the bioactive fibers are concentrated at the surface of the implant to create a surface comprised of at least 30% bioactive material, thereby providing enhanced bone ingrowth. The interweaving between the bone bioactive glass or ceramic fibers and the core of structural fibers overcomes the problems found in prior composite systems where the bioactive material delaminates from the polymer. Preferred bioactive materials include calcium phosphate ceramics and preferred structural fibers include carbon fibers. Further preferred bioactive materials include aluminum oxide at greater than 0.2%, by mole. Improved prosthetic implants and methods of affixing an implant are thus also disclosed.
A biocompatible composite of tows of bone bioactive fibers comprising at least 19% Na 2 O by mole and greater than 0.2% Al 2 O 3 by mole, said tows of bioactive fibers intermingled with tows of structural fibers in a nonbioabsorbable polymeric matrix.
Claim 2
Dependent Claim
44 words
A biocompatible composite of tows of bone bioactive fibers comprising at least 19% Na 2 O by mole and greater than 0.2% Al 2 O 3 by mole, said tows of bioactive fibers intermingled with tows of structural fibers in a nonbioabsorbable polymeric matrix.
Claim 3
Dependent Claim
40 words
The composite of claim 1, wherein the bone bioactive fibers are arranged in a predetermined distribution and a section of a surface of the composite to be affixed to bone is comprised of about 30% or more bone bioactive fibers.
Claim 4
Dependent Claim
13 words
The composite of claim 1 wherein the structural fiber is a carbon fiber.
Claim 5
Dependent Claim
20 words
The composite of claim 1 wherein the polymeric material is chosen from the group consisting of: polysulfone; PEEK; and PEKK.
Claim 6
Dependent Claim
35 words
The composite of claim 1, wherein the bone bioactive fibers comprise 40-60% SiO 2 , 19-30% Na 2 O, 10-21% CaO, 0-4% P 2 O 5 , and 0.2-1% Al 2 O 3 by mole.
Claim 7
Dependent Claim
35 words
The composite of claim 1, wherein the bone bioactive fibers comprise 45-55% SiO 2 , 19-30% Na 2 O, 15-20% CaO, 0-3% P 2 O 5 , and 0.2-1% Al 2 O 3 by mole.
Claim 8
Dependent Claim
23 words
The composite of claim 1, further comprising a modifier selected from the group consisting of K 2 O, MgO, and F 2 .
Claim 9
Dependent Claim
21 words
The composite of claim 1 wherein the bone bioactive fibers have a diameter of from about 5 to about 25 microns.