Modified Polymeric Materials And Methods Of Modifying Polymeric Materials

Abstract

Methods of forming polymeric articles using plasma treated polymer resins, and orthopedic implants comprising a polymeric article wherein the polymeric article has reactive groups bonded to polymer molecules in an interior region of the polymeric article.

1 . A method of forming a polymeric article suitable for use as an orthopedic implant, the method comprising:
 providing particles of a first polymer resin;   exposing the particles of the first polymer resin to a first plasma wherein the first plasma reacts with the particles of the first polymer resin to bond one or more selected reactive groups to the particles; and   consolidating the first polymer resin to form a polymeric article.   
     
     
         2 . The method of  claim 1  in which the plasma is formed from a gas selected from the group consisting of nitric oxide, carbon dioxide, ammonia, amine monomer, and combinations thereof. 
     
     
         3 . The method of  claim 1  in which the one or more selected reactive groups are selected from the group consisting of amines, amides, imides, carboxyl, carbonyl, hydroxyl, sulfonates, phosphates, perfluoro and combinations thereof. 
     
     
         4 . The method of  claim 1  further including blending the particles of the first polymer resin with an additive. 
     
     
         5 . The method of  claim 4  in which the additive is an antioxidant or biological agent. 
     
     
         6 . The method of  claim 5  in which the blending occurs after exposure of the particles to the first plasma. 
     
     
         7 . The method of  claim 1  further including exposing particles of a second polymer resin to a second plasma wherein the second plasma reacts with the particles of the second polymer resin to bond one or more selected reactive groups to the particles of the second resin;
 arranging the first and second resins relative to one another; and 
 consolidating the first and second resins to form a polymeric article that includes different reactive groups located in different regions of the polymeric article. 
 
     
     
         8 . The method of  claim 7  in which the arranging comprises mixing the first and second resins. 
     
     
         9 . The method of  claim 7  in which the first polymer resin and the second polymer resin comprise the same polymer. 
     
     
         10 . The method of  claim 1  in which consolidating comprises compression molding the polymer resin. 
     
     
         11 . The method of  claim 1  in which the first polymer resin is selected from the group consisting of as polyethylene, ultrahigh molecular weight polyethylene, polyaryletherketones, polypropylene, polyurethanes, acrylics, polyethylene-co-vinyl alcohol, nylon, polysulfones, polycarbonates, and polyacrylamides or combinations thereof. 
     
     
         12 . The method of  claim 1  wherein the particles of the first polymer resin include polymer molecules, and the method further comprises crosslinking the polymer molecules prior to or after consolidation. 
     
     
         13 . The method of  claim 12  in which the crosslinking comprises irradiating the polymeric article. 
     
     
         14 . The method of  claim 12  in which the reactive groups are crosslinking agents and wherein the reactive groups crosslink the polymer. 
     
     
         15 . A method of forming a polymeric article suitable for use as a medical implant, the method comprising:
 providing a plasma modified polymer resin; and   consolidating the polymer resin to form a polymeric article.   
     
     
         16 . The method of  claim 15  in which the polymer resin is selected from the group consisting of polyethylene, ultrahigh molecular weight polyethylene, polyaryletherketones, polypropylene, and combinations thereof. 
     
     
         17 . An orthopedic implant, comprising:
 an article comprising a polymer;   said article having an outer surface and an interior region;   said polymer including a plurality of polymer molecules having one or more reactive groups bonded thereto, wherein the reactive groups provide one or more of selected properties from the group consisting of crosslinks, lubricity, wettability, hydrophobicity, hydrophilicity, selected biological response, tissue attachment, protein binding and combinations thereof; and   the polymer molecules being located at least at the interior region of the polymeric article.   
     
     
         18 . The implant of  claim 17  in which the reactive groups are located substantially throughout the interior region and at exterior surface of the article. 
     
     
         19 . The implant of  claim 17  in which reactive groups are located in selective portions of the polymeric article. 
     
     
         20 . The implant of  claim 17  in which the properties are selected from the group consisting of from the group consisting of crosslinks, lubricity, wettability, hydrophobicity, hydrophilicity, selected biological response, tissue attachment, protein binding and combinations thereof.