Note: Descriptions are shown in the official language in which they were submitted.
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Foam Composite for the Repair or Regeneration of Tissue
Field of the Invention
The present invention relates generally to the field of
tissue repair and regeneration. More particularly the
present invention relates to porous biocompatible
bioabsorbable foams that have a gradient in composition
and/or microstructure that serve as a template for
tissue regeneration, repair or augmentation.
Background of the Invention
Open cell porous biocompatible foams have been
recognized to have significant poteritial for use in the
repair and regeneration of tissue. Early efforts in
tissue repair focused on the use of amorphous
biocompatible foam as porous plugs to fill voids in
bone. Brekke, et al. (U.S. Patent No. 4,186,448)
described the use of porous mesh plugs composed of
polyhydroxy acid polymers such as polylactide for
healing bone voids. Several attempts have been made in
the recent past to make TE scaffolds using different
methods, for example U.S. Patents 5,522,895 (Mikos) and
5,514,378 (Mikos, et al.) using leachables; U.S. Patents
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5,755,792 (Brekke) and 5,133,755 (Brekke) using vacuum
foaming techniques; U.S. Patents 5,716,413 (Walter, et
al.) and 5,607,474 (Athanasiou, et al.) using
precipitated polymer gel masses; U.S. Patents 5,686,091
(Leong, et al.) and 5,677,355 (Shalaby, et al.) using
polymer melts with fugitive compounds that sublimate at
temperatures greater than room temperature; and U.S.
Patents 5,770,193 (Vacanti, et al.) 5,769,899
(Schwartz, et al.) and 5,711,960 (Shikinami) using
textile-based fibrous scaffolds. Hinsch et al. (EPA
274,898) described a porous open cell foam of
polyhydroxy acids with pore sizes from about 10 to about
200 m for the in-growth of blood vessels and cells.
The foam described by Hincsh could also be reinforced
with fibers, yarns, braids, knitted fabrics, scrims and
the like. Hincsh's work also described the use of a
variety of polyhydroxy acid polymers and copolymers such
as poly-L-lactide, poly-DL-lactide, polyglycolide, and
polydioxanone. The Hincsh foams had the advantage of
having regular pore sizes and shapes that could be
controlled by the processing conditions, solvents
selected, and the additives.
However, the above techniques have limitations in
producing a scaffold with a gradient structure. Most of
the scaffolds are isotropic in form and function and
lack the anisotropic features of natural tissues.
Further, it is the limitation of prior art to make 3D
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scaffolds that have the ability to control the spatial
distribution of various pore shapes. The process that
is described to fabricate the microstructure controlled
foams is a low temperature process that offers many
advantages over other conventional techniques. For
example the process allows the incorporation of
thermally sensitive compounds like proteins, drugs and
other additives with the thermally and hydrolytically
unstable absorbable polymers.
Athanasiou et al. (U.S. Patent No. 5,607,474) have more
recently proposed using a two layer foam device for
repairing osteochondral defects at a location where two
dissimilar types of tissue are present. The Athanasiou
is device is composed of a firsL aiid second layer, prepared
in part separately, and joined together at a subsequent
step. Each of the scaffold layers is designed to have
stiffness and compressibility corresponding to the
respective cartilage and bone tissue. Since cartilage
and bone often form adjacent layers in the body this
approach is an attempt to more'clearly mimic the
structure of the human body. However, the interface
between the cartilage and bone in the human body is not
a discrete junction of two dissimilar materials with an
abrupt change in anatomical features and/or the
mechanical properties. The cartilage cells have
distinctly different cell morphology and orientation
depending on the location of the cartilage cell in
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relation to the underlying bone structure. The
difference in cartilage cell morphology and orientation
provides a continuous transition from the outer surface
of the cartilage to the underlying bone cartilage
interface. Thus the two layer system of Athanasiou,
although an incremental improvement, does not mimic the
tissue interfaces present in the human body.
Another approach to make three-dimensional laminated
foams is proposed by Mikos et al. (U.S. Patent No.
5,514,378). In this technique which is quite
cumbersome, a porous membrane is first prepared by
drying a polymer solution containing leachable salt
crystals. A three-dimensional structure is then
obtained by laminating several membranes together, which
are cut to a contour drawing of the desired shape.
One of the major weaknesses of the prior art regarding
three-dimensional porous scaffolds used for the
regeneration of biological tissue like cartilage is that
their microstructure is random. These scaffolds, unlike
natural tissue, do not vary in morphology or structure.
Further, current scaffolds do not provide adequate
nutrient and fluid transport for many applications.
Finally, the laminated structures are not completely
integrated and subjected to delamination under in vivo
conditions.
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Therefore, it is an object of the present invention to
provide a biocompatible, bioabsorbable foam that
provides a continuous transitional gradient of
morphological, structural and/or materials. Further, it
is preferred that foams used in tissue engineering have
a structure that provides organization at the
microstructure level that provides a template that
facilitates cellular invasion, proliferation and
differentiation that will ultimately result in
regeneration of functional tissue.
Summary of Invention
is The present inventiuii provides a composite comprising a
first layer that is a biocompatible filamentous layer
and a second layer of biocompatible foam. This composite
structure allows for the creation of structures with
unique mechanical properties. The fibrous layer allows
2o the composite to have variable mechanical strength
depending on the design, a different bioabsorption
profile, and a different microenvironment for cell
invasion and seeding, which are advantageous in a
variety of medical applications. The fibrous layer may
25 be made from a variety of biocompatible polymers and
blends of biocompatible polymers, which are preferably
bioabsorbable. The biocompatible foam may be either a
gradient foam or a channeled foam. The gradient foam
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has a substantially continuous transition in at least
one characteristic selected from the group consisting of
composition, stiffness, flexibility, bioabsorption rate,
pore architecture and/or microstructure. The gradient
foam can be made from a blend of absorbable polymers
that form compositional gradient transitions from one
polymeric material to a second polymeric material. In
situations where a single chemical composition is
sufficient for the application, the invention provides a
composite that may have microstructural variations in
the structure across one or more dimensions that may
mimic the anatomical features of the tissue (e.g.
cartilage, skin, bone etc.). The channeled foam
provides channels that extend through the foam to
is facilitate cell migration and nutrient flow throughout
the channeled foam.
The present invention also provides a method for the
repair or regeneration of tissue contacting a first
tissue with the composite described above at a location
on the composite that has appropriate properties to
facilitate the growth of said tissue. These composite
structures are particularly useful for the regeneration
of tissue between two or more different types of
tissues. For a multi-cellular system in the simplest
case, one cell type could be present on one side of the
scaffold and a second cell type on the other side of the
scaffold. Examples of such regeneration can be (a)
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vascular tissue: with smooth muscle on the outside and
endothelial cells on the inside to regenerate vascular
structures; (b) meniscal tissue: by implanting with
chondrocytes inside foam of the composite and orienting the
fibrous surface to the outside.
According to one aspect of the present invention,
there is provided a biocompatible composite comprising a
first biocompatible filamentous layer attached to a second
biocompatible foam layer wherein the biocompatible foam
layer comprises a gradient foam or a channeled foam wherein
the gradient foam has a first location and a second location
and a substantially continuous transition in at least one
characteristic selected from the group consisting of
composition, stiffness, flexibility, bioabsorption rate and
pore architecture from the first location to the second
location of said gradient foam and the channeled foam has a
first surface and a second surface with channels therein.
Brief Description of Figures
Figure 1 is a scanning electron micrograph of the
cross section of a random microstructure foam made from 5%
solution of 35/65 E-caprolactone-co-glycolide copolymer.
Figure 2 is a scanning electron micrograph of the
cross section of a foam with vertical open channels made
from 10% solution of 35/65 E-caprolactone-co-glycolide
copolymer.
Figure 3 is a scanning electron micrograph of the
cross section of a foam with architectural gradient made
from 10% solution of 35/65 s-caprolactone-co-glycolide
copolymer.
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Figure 4 is a scanning electron micrograph of the
cross section of a gradient foam made from a 50/50 blend of
40/60 c-caprolactone-co-(L)lactide copolymer and 35/65
c-caprolactone-co-glycolide copolymer.
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Figure 5 is a scanning electron micrograph of a cross
section of the top portion of a gradient foam made from
a 50/50 blend of 40/60 s-caprolactone-co- (L)lactide
copolymer and 35/65 e-caprolactone-co-glycolide
copolymer.
Figure 6 is a scanning electron micrograph of a cross
section of the bottom portion of a gradient foam made
from a 50/50 blend of 40/60 c-caprolactone-co-(L)lactide
copolymer and 35/65 s-caprolactone-co-glycolide
copolymer.
Figure 7 is a graphical presentation of cell culture
data, 7A, 7B and 7C.
Figure 8 is an anatomical sketch of cartilage tissue.
Figure 9A, 9B, and 9C are scanning electron micrographs
of a 0.5 mm foam made from a 50/50 blend of a 35/65 s-
caprolactone-co-glycolide copolymer and a 40/60 E-
caprolactone-co-(L)lactide copolymer with architecture
suitable for use as a skin scaffold. Figure 9A shows the
porosity of the surface of the scaffold that preferably
would face the wound bed. Figure 9B shows the porosity
of the surface of the scaffolding that would preferably
face away from the wound bed. Figure 9C shows a cross
section of the scaffold with channels running through
the thickness of the foam.
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Figure 10 is a dark field 40X photomicrograph of a
trichrome stained sample illustrating the cellular
invasion of the foam shown in Figure 9, eight days after
s implantation in a swine model.
Figure 11 is a 100X composite photomicrograph of a
trichrome stained sample illustrating the cellular
invasion of the foam shown in Figure 9 which also
contained PDGF, eight days after implantation in a swine
model.
Figure 12 is a photomicrograph of a cross-section of an
electrostatically spun fibrous layer fused to a foam
sui,st,rate (both ma_erials are 60/40 copolymers of
(L) lactide and E--caprolactone).
Figure 13 is a photomicrograph of the surface porosity
of the electrostatically spun layer shown in Figure 12.
Detailed Description of the Invention
This invention describes porous bioabsorbable polymer
foams that have novel microstructures. The features of
such foams can be controlled to suit a desired
application by choosing the appropriate conditions to
form the foam during lyophilization. These features in
absorbable polymers have distinct advantages over the
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prior art where the scaffolds are typically isotropic or
random structures. However, it is preferred that foams
used in tissue engineering (i.e. repair or regeneration)
have a structure that provides organization at the
microstructural level that provides a template that
facilitates cellular organization and regeneration of
tissue that has the anatomical, biomechanical, and
biochemical features of normal tissues. These foams can
be used to repair or regenerate tissue (including
io organs) in animals such as domestic animals, primates
and humans.
The features of such foams can be controlled to suit
desired application by selecting the appropriate
is conditions for lyophilization to obtain one o1 <<<ore of
the following properties: (1) interconnecting pores of
sizes ranging from about 10 to about 200 m (or greater)
that provide pathways for cellular ingrowth and nutrient
diffusion; (2) a variety of porosities ranging from
20 about 20% to about 98% and preferably ranging from about
80% to about 95%; (3)gradient in the pore size across
one direction for preferential cell culturing; (4)
channels that run through the foam for improved cell
invasion, vascularization and nutrient diffusion; (5)
25 micro-patterning of pores on the surface for cellular
organization; (6) tailorability of pore shape and/or
orientation (e.g. substantially spherical, ellipsoidal,
columnar); (7) anisotropic mechanical properties; (8)
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composite foams with a polymer composition gradient to
elicit or take advantage of different cell response to
different materials; (9) blends of different polymer
compositions to create structures that have portions
that will break down at different rates; (10) foams co-
lyophilized or coated with pharmaceutically active
compounds including but not limited to biological
factors such as RGD's, growth factors ( PDGF, TGF-(3,
VEGF, BMP, FGF etc.) and the like; (11) ability to make
3 dimensional shapes and devices with preferred
microstructures; and (12) lyophilization with other
parts or medical devices to provide a composite
structure. These controlled features in absorbable
polymers have distinct advantages over the prior art
ls where the scaffolds are typically isotropic or random
structures with no preferred morphology at the pore
level. However, it is preferred that foams used in
tissue scaffolds have a structure that provides
organization at the microstructure level and provides a
template that facilitates cellular organization that may
mimic natural tissue. The cells will adhere,
proliferate and differentiate along and through the
contours of the structure. This will ultimately result
in a cultured tissue that may mimic the anatomical
features of real tissues to a large extent.
For example, as shown in Figure 3 the orientation of the
major axis of the pores may be changed from being in the
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same plane as the foam to being oriented perpendicular
to the plane of the foam. As can be seen from Figure 3
the pore size can be varied from a small pore size
generally between about 30 m and about 50 m to a
larger size of from about 100 m to about 200 m in
porous gradient foams. Ideally the foam structure could
be created to facilitate the repair or regeneration of
human tissue junctions such as the cartilage to bone
junction present in joints. This foam would progress
lo from a small (i.e. about 30 m to about 150 m in
diameter) round pores to larger column-like pores (i.e.
about 30 m to about 400 m in diameter, preferably
about 100 m to about 400 m in diameter, in most cases
with a length to diameter ratio of at least 2). Foams
ls with channels are illustrated in F'igure 2 and Figure 3.
The channels formed by this process generally begin on
one surface of the foam and may traverse the thickness
of the foam. The channel's length is generally at least
two times the average pore diameter and preferably are
20 at least four times the average pore diameter and most
preferably at least eight times the average pore
diameter. Channels for most applications will be at
least 200 microns in length and may extend through the
thickness of the foam. The diameter of the channel will
25 be at least one time the size of the average pore
diameter and preferably at least 2 to 3 times the
average pore diameter. The channel size and diameter of
course will be selected based on the desired
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functionality of the channel such as cellular invasion,
nutrient diffusion or as an avenue for vascularization.
There are a number of biological tissues that
demonstrate gradient architectures. Examples of tissues
where a gradient scaffold could be used, include, but
are not limited to: bone, spine disc, articular
cartilage, meniscus, fibrocartilage, tendons, ligaments,
dura, skin, vascular grafts, nerves, liver, and
pancreas. The examples below only highlight a few
tissues where gradient scaffolds could be used. The
design of tissue engineered scaffolds to facilitate
development of these organ structures would benefit
greatly from the ability to process or create a gradient
architecture in the scaffold.
Cartilage
Articular cartilage covers the ends of all bones that
form articulating joints in humans and animals. The
cartilage acts in the joint as'a mechanism for force
distribution and as a bearing surface between different
bones. Without articular cartilage, stress
concentration and friction would occur to the degree
that the joint would not permit ease of motion. Loss of
the articular cartilage usually leads to painful
arthritis and decreased joint motion. A schematic
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showing the morphological features of a healthy
cartilage is shown in Figure 8.
Articular cartilage is an excellent example of a
naturally occurring gradient structure. Articular
cartilage is composed of four different zones that
include the superficial or tangential zone within the
first 10-20% of the structure (this includes the
articular surface), the middle zone which is 40-600 of
the middle structure, and the deep zone that is adjacent
to the tide mark, and a transition zone between the bone
and cartilage that is composed of calcified cartilage.
Subchondral bone is located adjacent to the tide mark
and this transitions into cancellous bone. In the
superficial or tangential zone, the coliagen fibrils are
parallel to the surface. The fibers are oriented to
resist shear forces generated during normal joint
articulation. The middle zone has a randomly arranged
organization of much larger diameter collagen fibers.
Finally, in the deep zone there are larger collagen
fiber bundles, which are perpendicular to the surface,
and they insert into the calcified cartilage. The cells
are speroidiol and tend to arrange themselves in a
columnar manner. The calcified cartilage zone has
smaller cells with relatively little cytoplasm.
A preferred embodiment of this invention would be to
generate a gradient foam structure that could act as a
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template for multiple distinct zones. These foam
structures could be fabricated in a variety of shapes to
regenerate or repair osteochondrial defects and
cartilage. One potential foam structure would be
cylindrical in shape with an approximate dimensions of
10mm in diameter and 10 mm in depth. The top surface is
would be approximately 1 mm thick and would be a low
porosity layer to control the fluid permeability. By
adopting a suitable processing method the surface
io porosity of the foam could be controlled. The porosity
of this skin like surface can be varied from completely
impervious to completely porous. Fluid permeability
would be controlled by surface porosity. Below such a
skin the structure would consist of three zones. An
is upper porous zone which lies adjacent to cartilage
tissue, a lower porous zone which lies adjacent to bone
tissue, and a transition zone between the upper and
lower porous zones. For articular cartilage, it is
currently preferred that the stiffness (modulus) of the
20 upper and lower porous layers at the time of
implantation be at least as stiff, as the corresponding
adjacent tissue. In such a case the porous layers will
be able to support the environmental loading and thereby
protect the invading cells until they have
25 differentiated and consolidated into tissue that is
capable of sustaining load. For example the porous
structure used for the superficial tangential zone could
have elongated pores and the orientation of the
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structure could be parallel to the surface of the host
cartilage. However, the deep zone may have a porosity
of about 80 to about 95 % with pores that are of the
order of 100 m (about 80 m to about 120 m). It is
expected that chondrocytes will invade this zone. Below
this, would be a zone with larger pores (about 100 m to
about 200 m) and a porosity in the range of about 50 to
about 80 %. Such 100 m to about 200 m porous foam
would have a structure such that the struts or walls of
the pores are larger and vertical to the load, similar
to the naturally occurring structure and to bear the
loads. Finally, at the bottom of this structure there
is a need for larger pores (about 150 m to about 300
m) with higher stiffness to be structurally compatible
ls with cancellous bone. The foam in this section could be
reinforced with ceramic particles or fibers made up of
calcium phosphates and the like.
Recent data generated in our laboratories support the
hypothesis that cell invasion can be controlled by pore
size. In these studies, a scaffold made of 95/5 mole
percent poly(L)lactide-co-s-caprolactone) with an
approximate pore size of about 80 m had chondrocyte
invasion of about 30 cells/mm2 of the scaffold (under
static conditions). Scaffolds made of 40/60 mole
percent poly(E-caprolactone-co-(L)lactide) with a larger
approximate pore size of about 100 m had a
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statistically significantly greater cellular invasion of
50 cells/mm2(under static conditions). In both cases the
cells were bovine chondrocytes. A very simple gradient
structure with a variation of pore sized from about 80
m to about 150 m would provide a structure where
chondrocytes would more easily invade the area with
larger pores. The area with smaller pores would be void
of chondrocytes or would be filled with a second cell
types (e.g., fibroblasts).
In a compositionally gradient foam a blend of two or
more elastomeric copolymers or in combination with high
modulus semi-crystalline polymers along with additives
such as growth factors or particulates can be chosen
such that first a desired pore gradient is developed
with a preferred spatial organization of the additives.
Then using a variety of the approaches referred to in
the preferred methods of making gradient foams, a
compositional gradient can be superimposed primarily due
to the differences in the polymer-solvent phase
separation behavior of each system. Such a gradient
foam structure would elicit a favorable response to
chondrocytes or osteoblasts depending on the spatial
location.
Further, the purpose of a functional gradient is to more
evenly distribute the stresses across a region through
which mechanical and/or physical properties are varying
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and thereby alleviate the stress concentrating effects
of a sudden interface. This more closely resembles the
actual biological tissues and structures, where
structural transitions between differing tissues such as
cartilage and bone are gradual. Therefore, it is an
object of the present invention to provicie an implant
with a functional gradient between material phases. The
present invention provides a multi-phasic functionally
graded bioabsorbable implant with attachrnent means for
use in surgical repair of osteochondral defects or sites
of osteoarthritis. Several patents have proposed
systems for repairing cartilage that could be used with
the present inventive porous scaffolds. For example,
U.S. Patent 5,769,899 describes.a device for repairing
cartilage defects and U.S. Patent 5,713,374 describes
securing cartilage repair devices with bone anchors.
Bone
Gradient structures naturally occur for the bone /
cartilage interface. In a study in our :Laboratories, we
have demonstrated that material differences
significantly influence cell function. In initial and
long-term response of primary osteoblasts to polymer
films (95/5 L-lactide-co-glycolide copolymer, 90/10
glycolide-co-(L)lactide copolymer, 95/5 L-lactide-co-s-
caprolactone copolymer, 75/25 glycolide-co-(L)lactide
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copolymer and 40/60 s-caprolactone-co- (L)lactide
copolymer and knitted meshes (95/5 (L)lactide-co-
glycolide and 90/10 glycolide-co-(L)lactide copolymers)
were evaluated in vitro. The results demonstrated that
osteoblasts attached and proliferated well on all the
biodegradable polymer films and meshes following 6-day
incubation. None of the tested polymer films, except a
40/60 s-caprolactone-co-(L)lactide copolymer film,
demonstrated significant enhancement in differentiation
of primary rat osteoblasts as compared to tissue culture
polystyrene (control). Films made of 40/60 -
caprolactone-co-(L)lactide promoted enhanced
differentiation of cultured osteoblasts as demonstrated
by increased alkaline phosphatase activity and
osteoclacin mRNA expression as compared to the other
films and TCPS. Hence, it is clear that different
absorbable materials will significantly alter cell
function and differentiation. By identifying the
optimal materials for cell growth and differentiation a
composite materials with a gradient composition could be
utilized to optimize tissue regeneration with different
cell types in the same scaffold.
Therefore, for bone repair or regeneration devices or
scaffoldings, a device made from a homopolymer,
copolymer (random, block, segmented block, tappered
blocks, graft, triblock, etc.) having a linear, branched
or star structure containing c-caprolactone is
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especially preferred. Currently preferred are aliphatic
polyester copolymers containing in the range of from
about 30 weight percent to about 99 weight percent c-
caprolactone. Suitable repeating units that may be
,5 copolymerized with E-caprolactone are well known in the
art. Suitable comonomers that may be copolymerized with
s-caprolactone include , but are not limited to lactic
acid, lactide (including L-, D-, meso and D,L mixtures),
glycolic acid, glycolide, p-dioxanone (1,4-dioxan-2-
one), trimethylene carbonate (1,3-dioxan-2-one), b-
valerolactone, (3-butyrolactone, E-decalactone, 2,5-
diketomorpholine, pivalolactone, a,a-
diethylpropiolactone, ethylene carbonate, ethylene
oxalate, 3-methlT1_-1.,4-dioxane-2,5-dione, 3,3-diethyl-
1,4-dioxan-2,5-dione, y-butyrolactone, 1,4-dioxepan-2-
one, 1,5-dioxepan-2-one, 6,6-dimethyl-dioxepan-2-one,
6,8-dioxabicycloctane-7-one and combinations thereof.
Preferred medical devices or tissue scaffoldings for
bone tissue repair and/or regeneration containing
bioabsorbable polymers made from E-caprolactone include
but are not limited to the porous foam scaffoldings
(such as described in this application), fibrous three
dimensional, spun, nonwoven, woven, knitted, or braided
tissue scaffoldings, composite containing reinforcing
fibers, matrices and combinations thereof.
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Skin
Another example of a tissue that has a gradient
structure is skin. The basic structure of skin has two
distinct, but well integrated layers where the thickness
of each layer varies at different locations of the body.
The outer layer or epidermis, is avascular and mainly
consists of keratinocytes with smaller numbers of immune
cells (Langerhan cells) and pigmented cells
(melanocytes). The keratinocytes produce keratin fibers
and corneocyte envelopes, which gives the epidermis its
durability and protective capabilities. The development
of these structures is completely dependent upon the
differentiation state of the epidermis. The epidermis
forms a stratified epithelium, with different protein
expression patterns, as the cells move further away from
the basement membrane. This stratified layer of
differentially expressing cells must be formed for
maintenance of epidermal function. Below the epidermis
is the dermis, which is a dense irregular connective
tissue that is highly vascular. This layer is heavily
populated with collageneic and elastic fibers, which
give it its exceptional elasticity and strength.
Fibroblasts are the main cell types in this layer.
Between these two layers is the basement membrane, which
serves as the site of attachment for epidermal cells and
serves also to regulate their function and
differentiation. The layer of keratinocytes, which
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attaches directly to the basement membrane, are cuboidal
in shape and highly aligned. This attachment and
architecture are critical requirements driving the
ultimate production of the higher squamous structures in
the epidermis. The basal layer provides a source of
precursor cells for repair and replacemerit of the
epidermis. The squamous layers provide strength and
resistance to insult and infection.
Any material used for replacement of skin must be able
to entice invasion of fibroblasts or other cells
necessary to produce the dermal components of the healed
tissue., Additionally, the material must not inhibit,
and preferably should enhance, the rate of re-
epithelialization in such a fashion that a discreet,
epidermal basal layer is formed. Materials that permit
invasion into the scaffold by migrating keratinocytes
can produce partially differentiated cells.
Consequently, control of access of particular cell types
and a porous design that facilitates the regeneration of
the natural tissue can have functional benefits. Now
refer to Figures 9A, 9B and 9C which illustrates the
microstructure of this foam scaffold. Figures 10 (100X
magnification) and 11 (40X magnification composite
picture) provide photomicrographic evidence of the
invasion of fibroblasts, macrophages, macrophage giant
cells and endothelial-like cells into the a 0.5 mm foam.
The foam tissue scaffolding shown in both pictures
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was a 50:50 blend of s-caprolactone-co-glycolide
copolymer and c-caprolactone-co-lactide copolymer (made
as described in Example 7). The pictures were taken at
8 days after implantation in 1.5 cm X 1.5 cm X 0.2 cm
excisional wound model in a Yorkshire pig model.
Complete incorporation of the matrix into the
granulation tissue bed is evident in both pictures. The
dense fibrous tissue above the foam tissue scaffolding
appears to provide a suitable substrate for the over
growth of epidermis. PDGF was incorporated into the
foam tissue scaffolding shown in Figure 11. In
compromised wound healing models the addition of a
growth factor such as PDGF may in fact be necessary.
From our initial studies it appears that it is desirable
to use as a skin scaffold a foam tissue scaffold having
a thickness of from about 150 m to about 3 mm,
preferably the thickness of the foam may be in the range
of from about 300 m to about 1500 m and most
preferably about 500 to about 1000 m. Clearly
different skin injuries (i.e. diabetic ulcers, venous
stasis ulcers, decubitis ulcers, burns etc.) may require
different foam thickness. Additionally, the patient's
condition may necessitate the incorporation of growth
factors, antibiotics and antifungal compounds to
facilitate wound healing.
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Vascular grafts
The creation of tubular structures with gradients may
also be of interest. In vascular grafts, having a tube
with pores in the outer diameter which transitions to
smaller pores on the inner surface or visa versa may be
useful in the culturing of endothelial cells and smooth
muscle cells for the tissue culturing of vessels.
Multilayered tubular structures allow the regeneration
of tissue that mimics the mechanical and/or biological
characteristics of blood vessels will have utility as a
vascular grafts. Concentric layers, made from different
compositions under different processing conditions could
i5 have tailored mechanical properties, bioabsorption
properties, and tissue ingrowth rates. The inner most,
or luminal layer would be optimized for
endothelialization through control of the porosity of
the surface and the possible addition of a surface
treatment. The outermost, or adventitial layer of the
vascular graft would be tailored to induce tissue
ingrowth, again by optimizing the porosity (percent
porosity, pore size, pore shape and pore size
distribution) and by incorporating bioactive factors,
pharmaceutical agents, or cells. There may or may not
be a barrier layer with low porosity between these two
porous layers to increase strength and decrease leakage.
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Composition of foams
A variety of absorbable polymers can be used to make
foams. Examples of suitable biocompatible,
bioabsorbable polymers that could be used include
polymers selected from the group consisting of aliphatic
polyesters, poly(amino acids), copoly(ether-esters),
polyalkylenes oxalates, polyamides,
poly(iminocarbonates), polyorthoesters, polyoxaesters,
polyamidoesters, polyoxaesters containing amine groups,
poly(anhydrides), polyphosphazenes, biomolecules (i.e.
biopolymers sucha as collagen, elastin, bioabsorbable
starches, ect.) and blends thereof. For the purpose of
this invention aliphatic polyesters include but are not
limited to homopolyrners axid copolymers of lactide (which
includes lactic acid, D-,L- and meso lactide), glycolide
(including glycolic acid), s-caprolactone, p-dioxanone
(1,4-dioxan-2-one), trimethylene carbonate (1,3-dioxan-
2-one), alkyl derivatives of trimethylene carbonate, 8-
valerolactone, P-butyrolactone, y-butyrolactone, s-
decalactone, hydroxybutyrate (repeating units),
hydroxyvalerate (repeating units), 1,4-dioxepan-2-one
(including its dimer 1,5,8,12-tetraoxacyclotetradecane-
7,14-dione), 1,5-dioxepan-2-one, 6,6-dimethyl-l,4-dioxan-
2-one 2,5-diketomorpholine, pivalolactone, alpha,
alpha-diethylpropiolactone, ethylene carbonate, ethylene
oxalate, 3-methyl-1,4-dioxane-2,5-dione, 3,3-diethyl-
1,4-dioxan-2,5-dione, 6,8-dioxabicycloctane-7-one and
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polymer blends thereof. Poly(iminocarbonate) for the
purpose of this invention include as described by
Kemnitzer and Kohn, in the Handbook of Biodegradable
Polymers, edited by Domb, Kost and Wisemen, Hardwood
Academic Press, 1997, pages 251-272. Copoly(ether-
esters) for the purpose of this invention include those
copolyester-ethers described in "Journal of Biomaterials
Research", Vol. 22, pages 993-1009, 1988 by Cohn and
Younes and Cohn, Polymer Preprints (ACS Division of
Polymer Chemistry) Vol. 30(1), page 498, 1989 (e.g.
PEO/PLA). Polyalkylene oxalates for the purpose of this
invention include Patent Nos. 4,208,511; 4,141,087;
4,130,6,39; 4,140,678; 4,105,034; and 4,205,399.
Polyphosphazenes, co-, ter- and higher order mixed monomer
based polymers made from L-lactide, D,L-lactide, lactic acid,
glycolide, glycolic acid, para-dioxanone, trimethylene
carbonate and E-caprolactone such as are described by
Allcock in The Encyclopedia of Polymer Science, Vol. 13,
pages 31-41, Wiley Intersciences, John Wiley & Sons,
1988 and by Vandorpe, Schacht, Dejardin and Lemmouchi in
the Handbook of Biodegradable Polymers, edited by Domb,
Kost and Wisemen, Hardwood Academic Press, 1997, pages 161-182.
Polyanhydrides from diac~ds of the form HOOC-C6H4-O- (CH2)m-O-C6H4-COOH
where m is an integer in the range of from 2 to 8 and copolymers
thereof with aliphatic alpha-omega diacids of up to 12 carbons.
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Polyoxaesters, polyoxaamides and polyoxaesters
containing amines and/or amido groups are described in
one or more of the following U.S. Patent Nos. 5,464,929;
5,595,751; 5,597,579; 5,607,687; 5,618,552; 5,620,698;
5,645,850; 5,648,088; 5,698,213; 5,700,583; and
5,859,150. Polyorthoesters such as those described by Heller
in Handbook of Biodegradable Polymers, edited by Domb, Kost and
Wisemen, Hardwood Academic Press, 1997, pages 99-118.
Io Currently aliphatic polyesters are the absorbable
polymer,s that are preferred for making gradient foams.
Aliphatic polyesters can be homopolymers, copolymers
(random, block, segmented, tappered blocks, graft,
triblock,etc.) having a linear, branched or star
structure. Preferred are linear copolymers. Suitable
monomers for making aliphatic homopolymers and
copolymers may be selected from the group consisting of,
but are not limited, to lactic acid, lactide (including
L-, D-, meso and D,L mixtures), glycolic acid,
glycolide, E-caprolactone, p-dioxanone (1,4-dioxan-2-
one), trimethylene carbonate (1,3-dioxan-2-one), delta-
valerolactone, beta-butyrolactone, epsiloii-decalactone,
2,5-diketomorpholine, pivalolactone, alpha, alpha-
diethylpropiolactone, ethylene carbonate, ethylene
oxalate, 3-methyl-l,4-dioxane-2,5-dione, 3,3-diethyl-
1,4-dioxan-2,5-dione, gamma-butyrolactone, 1,4-dioxepan-
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2-one, 1,5-dioxepan-2-one, 6,6-dimethyl-dioxepan-2-one,
6,8-dioxabicycloctane-7--one and combinations thereof.
Elastomeric copolymers also are particularly useful in
s the present invention. Suitable bioabsorbable
biocompatible elastomers include but are not limited to
those selected from the group consisting of elastomeric
copolymers of s-caprolactone and glycolide (preferably
having a mole ratio of s-caprolactone to glycolide of
from about 35:65 to about 65:35, more preferably from
45:55 to 35:65) elastomeric copolymers of s-caprolactone
and lactide, including L-lactide, D-lactide blends
thereof or lactic acid copolymers (preferably having a
mole ratio of s-caprolactone to lactide of from about
35:65 to about 65:35 and more preferably from 45:55 to
30:70 or from about 95:5 to about 85:15) elastomeric
copolymers of p-dioxanone (1,4-dioxan-2-one) and lactide
including L-lactide, D-lactide and lactic acid
(preferably having a mole ratio of p-dioxanone to
lactide of from about 40:60 to about 60:40) elastomeric
copolymers of E-caprolactone and p-dioxanone (preferably
having a mole ratio of E-caprolactone to p-dioxanone of
from about from 30:70 to about 70:30) elastomeric
copolymers of p-dioxanone and trimethylene carbonate
(preferably having a mole ratio of p-dioxanone to
trimethylene carbonate of from about 30:70 to about
70:30), elastomeric copolymers of trimethylene carbonate
and glycolide (preferably having a mole ratio of
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trimethylene carbonate to glycolide of from about 30:70
to about 70:30), elastomeric copolymer of trimethylene
carbonate and lactide including L-lactide, D-lactide,
blends thereof or lactic acid copolymers (preferably
having a mole ratio of trimethylene carbonate to lactide
of from about 30:70 to about 70:30) and blends thereof.
Examples of suitable bioabsorbable elastomers are
described in U.S. Patent Nos. 4,045,418; 4,057,537 and
5,468,253 all hereby incorporated by reference. These
elastomeric polymers will have an inherent viscosity of
from about 1.2 dL/g to about 4 dL/g, preferably an
inherent viscosity of from about 1.2 dL/g to about 2
dL/g and most preferably an inherent viscosity of from
about 1.4 dL/g to about 2 dL/g as determined at 25 C in a
0.1 gram per deciliter (g/dL) solution of polymer in
hexafluoroisopropanol (HFIP).
Preferably, the elastomers will exhibit a high percent
elongation and a low modulus, while possessing good
tensile strength and good recovery characteristics. In
the preferred embodiments of this invention, the
elastomer from which the foams are formed will exhibit a
percent elongation greater than about 200 percent and
preferably greater than about 500 percent. There
properties, which measure the degree of elasticity of
the bioabsorbable elastomer, are achieved while
maintaining a tensile strength greater than about 500
psi, preferably greater than about 1,000 psi, and a tear
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strength of greater than about 50 lbs/inch, preferably
greater than about 80 lbs/inch.
The polymer or copolymer suitable for forming a gradient
s foam for tissue regeneration depends on several factors.
The chemical composition, spatial distribution of the
constituents, the molecular weight of the polymer and
the degree of crystallinity all dictate to some extent
the in-vitro and in-vivo behavior of the polymer.
However, the selection of the polymers to make gradient
foams for tissue regeneration largely depends on (but
not limited to) the following factors: (a) bio-
absorption (or bio-degradation) kinetics; (b) in-vivo
mechanical performance; and (c) cell response to the
1.s material in terms of cell attachment, proliferation,
migration and differentiation and (d) biocompatibility.
The ability of the material substrate to resorb in a
timely fashion in the body environment is critical. But
the differences in the absorption time under in-vivo
conditions can also be the basis for combining two
different copolymers. For example a copolymer of 35:65
s-caprol.actone and glycolide (a relatively fast
absorbing polymer) is blended with 40:60 c-caprolactone
and (L)lactide copolymer (a relatively slow absorbing
polymer) to form a foam. Such a foam could have several
different physical structures depending upon the
processing technique used. The two constituents can be
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either randomly inter-connected bicontinuous phases, or
the constituents can have a gradient through the
thickness or a laminate type composite with a well
integrated interface between the two constituent layers.
The microstructure of these foams can be optimized to
regenerate or repair the desired anatomical features of
the tissue that is being engineered.
One preferred embodiment of the present invention is to
use polymer blends to form structures which transition
from one composition to another composition in a
gradient like architecture. Foams having this gradient
architecture are particularly advantageous in tissue
engineering applications to repair or regenerate the
i5 structure of iiaturally occurring tissue such as
cartilage (articular, meniscal, septal, tracheal etc.),
esophaguses, skin, bone and vascular tissue. For
example by blending an elastomer of s-caprolactone-co-
glycolide with s-caprolactone-co-lactide (i.e. with a
mole ratio of about 5:95) a foam may be formed that
transitions from a softer spongy foam to a stiffer more
rigid foam similar to the transition from cartilage to
bone. Clearly other polymer blends may be used for
similar gradient effects or to provide different
gradients such as different absorption profiles, stress
response profiles, or different degrees of elasticity.
Additionally, these foams can be used for organ repair
replacement or regeneration strategies that may benefit
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from these unique scaffolds, including but are not
limited to, spine disc, dura, nerve tissue, liver,
pancreas, kidney, bladder, tendons, ligaments and breast
tissues.
These elastomeric polymers may be foamed by
lyophilization, supercritical solvent foaniing (i.e., as
described in EP 464,163 Bl), gas injection extrusion,
gas injection molding or casting with an extractable
material (i.e., salts, sugar or any other means known to
those skilled in the art). Currently it is preferred to
prepare bioabsorbable, biocompatible elastomeric foams
by lyophilization. Suitable methods for lyophilizing
elastomeric polymers to form foams is described in the
Examples and in U.S. Patent No. 6,355,699.
The foams that are made in this invention are made by a
polymer-solvent phase separation technique with
modifications to the prior art that unexpectedly creates
gradients in the foam structure. Generally, a polymer
solutio,n can be separated into two phases by any one of
the four techniques: (a) thermally induced
gelation/crystalization; (b) non-solvent induced
separation of solvent and polymer phases; (c) chemically
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induced phase separation, and (d) thermally induced
spinodal decomposition. The polymer solution is
separated in a controlled manner into either two
distinct phases or two bicontinuous phases. Subsequent
removal of the solvent phase usually leaves a porous
structure of density less than the bulk polymer and
pores in the micrometer ranges (ref. "Microcellular
foams via phase separation" by A. T. Young, J. Vac. Sci.
Technolol. A 4(3), May/Jun 1986). The steps involved in
the preparation of these foams consists of choosing the
right solvents for the polymers that needs to be
lyophilized and preparing a homogeneous solution. Next,
the polymer solution is subjected to a freezing and
vacuum drying cycle. The freezing step phase separates
is the polymer solution and vacuum drying step removes the
solvent by sublimation and/or drying leaving a porous
polymer structure or an interconnected open cell porous
foam.
Suitable solvents that should be generally suited as a
starting place for selecting a'solvent for the preferred
absorbable aliphatic polyesters include but are not
limited to solvents selected from a group consisting of
formic acid, ethyl formate, acetic acid,
hexafluoroisopropanol (HFIP),cyclic ethers (i.e. THF,
DMF, and PDO), acetone, acetates of C2 to C5 alcohol
(such as ethyl acetate and t-butylacetate),glyme (i.e.
monoglyme, ethyl glyme, diglyme, ethyl diglyme,
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triglyme, butyl diglyme and tetraglyme) methylethyl
ketone, dipropyleneglycol methyl ether, lactones (such
as y-valerolactone, b-valerolactone, R-butyrolactone, y-
butyrolactone) 1,4-dioxane, 1,3-dioxolane, 1,3-
dioxolane-2-one (ethylene carbonate), dimethlycarbonate,
benzene, toluene, benzyl alcohol, p-xylene, naphthalene,
tetrahydrofuran, N-methyl pyrrolidone,
dimethylformamide, chloroform, 1,2-dichloromethane,
morpholine, dimethylsulfoxide, hexafluoroacetone
sesquihydrate (HFAS), anisole and mixtures thereof.
Among these solverits, the preferred solvent is 1,4-
dioxane. A homogeneous solution of the polymer in the
solvent-is prepared using standard techniques.
Accordingly, as will be appreciated, the applicable
polymer concentration or amount of solvent, which may be
utilized, will vary with each system. Suitable phase
diagram curves for several systems have already been
developed. However, if an appropriate curve is not
available, this can be readily developed by known
techniques. For example, a suitable technique is set
forth in Smolders, van Aartsen and Steenbergen, Kolloid-
-Z. u. Z. Polymere, 243, 14 (1971). As a general
guideline the amount of polymer in the solution can vary
from about 0.5% to about 90% and preferably will vary
from about 0.5% to about 30% by weight depending to a
large extent on the solubility of the polymer in a given
solvent and the final properties of the foam desired.
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Additionally, solids may be added to the polymer-solvent
system. The solids added to the polymer-solvent system
preferably will not react with the polymer or the
solvent. Suitable solids include materials that promote
tissue regeneration or regrowth, buffers, reinforcing
materials or porosity modifiers. Suitable solids
include, but are not limited to, particles of
demineralized bone, calcium phosphate particles, or
calcium carbonate particles for bone repair, leachable
solids for pore creation and particles of bioabsorbable
polymers not soluble in the solvent system as
reinforcing or to create poresas they are absorbed.
Suitable leachable solids include but are not limited
ls nontoxic leachable materials selected from the group
consisting of salts (i.e. sodium chloride, potassium
chloride, calcium chloride, sodium tartrate, sodium
citrate, and the like) biocompatible mono and
disaccharides (i.e. glucose, fructose, dextrose,
maltose, lactose and sucrose), polysaccharides (i.e.
starch, alginate), water soluble proteins (i.e. gelatin
and agarose). Generally all of these materials will have
an average diameter of less than about lmm and
preferably will have an average diameter of from about
50 to about 500 m. The particles will generally
constitute from about 1 to about 50 volume percent of
the total volume of the particle and polymer-solvent
mixture (wherein the total volume percent equals 100
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volume percent). The leachable materials can be removed
by immersing the foam with the leachable material in a
solvent in which the particle is soluble for a
sufficient amount of time to allow leaching of
substantially all of the particles, but which does not
dissolve or detrimentally alter the foam. The preferred
extraction solvent is water, most preferably distilled-
deionized water. This process is described in U.S.
patent No. 5,514,378 (see colunm 6). Preferably the foam will be
dried after the leaching process is complete at low
temperature and/or vacuum to minimize hydr.olvsis of the
foam un~ess accelerated absorption of the foam is
desired.
is After the polymer solvent mixture is formed the mixture
is then solidified. For a specific polymer-solvent
system, the solidification point, the melt temperature
and the apparent glass transition of the polymer-solvent
system can be determined using standard differential
20' scanning calorimetric (DSC) techniques. In theory, but
in no way limiting the scope of the preserit invention,
it is believed that as a polymer solvent system is
cooled down an initial solidification occurs at about or
below the freezing point of the solvent. This
25 corresponds to the freezing of a substantial portion of
the solvent in the system. The initial freezing appears
as a first exothermic peak. A second freezing point
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occurs when the remaining solvent associated with the
polymer solidifies. The second freezing point is marked
by a second exothermic peak. The apparent Tg is the
temperature at which the fully frozen system displays
the first endothermic shift on reheating.
An important parameter to control is the rate of
freezing of the polymer-solvent system. The type of
pore morphology that gets locked in during the freezing
step is a function of the solution thermodynamics,
freezing rate, temperature to which it is cooled,
concentration of the solution, homogeneous or
heterogenous nucleation etc. Detailed description of
these phase separation phenomenon can be found in the
references provided herein ("Microcellular foams via
phase separation" by A. T. Young, J. Vac. Sci. Technol.
A 4(3), May/Jun 1986; and "Thermodynamics of Formation
of Porous Poymeric Membrane from Solutions" by S.
Matsuda, Polymer J. Vol. 23, No. 5, pp 435-444, 1991).
The polymer solution previously described can be
solidified in a variety of manners such as placing or
injecting the solution in a mold and cooling the mold in
an appropriate bath or on a refrigerated shelf.
2s Alternatively, the polymer solution can be atomized by
an atomizer and sprayed onto a cold surface causing
solidification of the spray layer by layer. The cold
surface can be a medical device or part thereof or a
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film. The shape of the solidified spray will be similar
to the shape of the surface it is sprayed onto.
Alternatively, the mixture after solidification can be
cut or formed to shape while frozen. Using these and
other processes the foams can be made or molded in a
variety of shapes and sizes (i.e. tubular shapes,
branched tubular shapes, spherical shapes, hemispherical
shapes, three-dimensional polygonal shapes, ellipsoidal
shapes (i.e. kidney shaped), toroidal shapes, conical
shapes, frusta conical shapes, pyramidal shapes, both as
solid and hollow constructs and combination thereof).
Alternatively, another method to make shaped foamed
parts is to use a cold finger (a metal part whose
ls suzface replesents the inside of the part we want to
fabricate). The cold finger is dipped into a mixture of
polymer in an appropriate solvent and removed. This is
rnuch like dipping an ice cream pop into warm chocolate
that freezes to a hard, cold skin, or dipping a form
into a latex of rubber to form gloves or condoms. The
thickness and morphology of the' foam produced are a
function of the temperature, dwell time and withdrawal
rate of the cold finger in the mixture. Longer dwell,
colder finger and slower withdrawal will produce a
2s thicker coating. After withdrawal, the cold finger is
placed on a fixture of large thermal mass that is in
contact with the refrigerated tray of the lyophilizer.
From this point the primary and secondary drying
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processes are as described above. This method is
particularly well suited to making tubes, branched
tubular structures or sleeves that may be shaped to fit
devices or portions of an animal's anatomy (for repair,
regeneration or augmentation of tissue).
Additionally, the polymer solution can be solidified
with various inserts incorporated with the solution such
as films, scrims, woven, nonwoven, knitted or braided
lo textile structures. Additionally, the solution can be
prepared in association with another structure such an
orthopedic implant (e.g. screws, pins, nails, and
plates), or vascular or branched tubular construct (as a
scaffold for a vascularized or ducted organ). These
inserts will be made of at least one biocompatible
material and may be non-absorbable, absorbable or a
combination thereof.
The polymer solution in a mold undergoes directional
cooling through the wall of the mold that is in contact
with the freeze dryer shelf, which is subjected to a
thermal cycle. The mold and its surface can be made
from virtually any material that does not interfere with
the polymer-solvent system, though it is preferred to
have a highly conducting material. The heat transfer
front moves upwards from the lyophilizer shelf through
the mold wall into the polymer solution. The instant
the temperature of the mixture goes below the gellation
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and/or freezing point the mixture also phase separates.
The morphology of this phase separated system is locked
in place during the freezing step of the lyophilization
process and the creation of the open pores is initiated
by the onset of vacuum drying resulting in the
sublimation of the solvent. However, the mixture in
container or mold that is cooled from a heat sink will
solidify prior to completely freezing. Although the
mixture may appear solid, initially there appears to be
some residual solvent associated with the polymer that
has not cystallized. It is theorized, but in no way
limiting the present invention, that a freezing front
inoves through the ridxture from the heat sink to complete
the solidification after the mixture has apparently
solidified. The material in front of the freezing front
at a given time will not be as cold as the material
behind the front and will not be in a completely frozen
state.
We have discovered that if a vacuum is applied to the
apparently solid polymer-solvent mixture immediately
after it appears to solidify, a foam with a gradient
structure having variable pore size and structure as
well as channels can be created. Therefore, timing of
the onset of the sublimation process (by pressure
reduction i.e. vacuum drying) is a critical step in the
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process to create transitions in the structure. The
timing of the onset of sublimation will be affected by
the thickness of the foam being made, concentration of
the solution, rate of heat transfer, and
directionalities of the heat transfer. Those skilled in
the art will appreciate that this process can be
monitored and characterized for specific polymer-solvent
systems by using thermocouples and monitoring the heat
transfer rates of the foams at various depths and
locations in the device being foamed. By controlling the
sublimation process, structures with a gradient in pore
morphology and anisotropy may be created. This process
can lead to the creation of microstructures that mimic
tissues such as cartilage, bone and. skin. For example,
channels will generally be fornied if a vacuuiii is pulled
immediately after the solution apparently solidifies.
However, if the same solution is allowed to solidify
further the foam will have larger pores closer to the
surface where the vacuum is being drawn (opposite the
heat sink) and smaller pores closer to the heat sink.
This process is the antitheses of the prior art process
that focused on creating foams with a uniform
microstructure (randomly interconnected pores), whereby
the whole solution is completely frozen. And vacuum
drying is applied only after a considerable amount of
time is given for the completion of desired phase
separation (U.S. Patents 5,755,792 (Brekke); 5,133,755
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(Brekke); 5,716,413 (Walter, et al.); 5,607,474
(Athanasiou, et al.); 5,686,091 (Leong, et al.);
5,677,355 (Shalaby, et al.); and European disclosures
E0274898 (Hinsch) and EPA 594148 (Totakura)).
Foams with various structures are shown in Figures 2, 3,
and 4. For example, as shown in Figure 3 the
orientation of the major axis of the pores may be
changed from being in the same plane as the foam to
being oriented perpendicular to the plane of the foam.
By way of theory, but in no way limiting the scope of
this invention, it is believed that this in conventional
foam processing as the solvent crystallizes a freezing
front moves through the solution solidifying the
solution in crystalline layers parallel to the freezing
front. However, if a vacuum is pulled before the
solution completely freezes, the morphology of the foam
results in pores being formed generally aligned parallel
to the vacuum source. As is illustrated in Figure 3.
As can be seen from Figure 3 the pore size can be varied
from a small pore size generally between about 10 m and
about 60 m to a larger size of from about 60 m to
about 200 m in a porous gradient foam. Again this
results from pulling a vacuum on the apparently
solidified solution before it is completely solidified.
The polymer concentration in the solution and the
cooling rates are also important parameters in
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controlling the cell size. Ideally the foam structure
could be created to serve as a template to restore human
tissue junctions such as the cartilage to bone junction
present in joints. This foam would progress form a
small round pores to larger column-like (i.e. with a
diameter to length ratio of at least 2 to 1) pores.
Additionally, the stiffness of the foam can controlled
by the foams structure or blending two different
polymers with different Young's moduli.
Foams can also have channels as is illustrated in Figure
2. The channels formed by this process may traverse the
thickness of the foam and generally range in diameter
from about 30 to about 200 m in diameter. The channels
generally are at least two times the channel's average
diameter and preferably are at least four times the
channel's average diameter and most preferably at least
eight times the channel's average diameter. The channel
size and diameter of course will be selected based on
the desired functionality of the channel such as cell
invasion, nutrient diffusion or as a avenue for
vascularization.
One skilled in the art can easily visualize that such a
directionality can be created in any three dimensions by
designing an appropriate mold and subjecting the walls
of such a mold to different temperatures if needed. The
following types of gradient structures can be made by
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variation in the pore size and/or shape through the
thickness with a uniform composition: pores of one type
and size for a certain thickness followed by another
type and size of pores, etc; compositional gradient with
predominantly one composition on one side and another
one on the other with a transition from one entity to
the other; a thick skin comprising low porosity of low
pore size layer followed by a large pore size region;
foams with vertical pores with a spatial organization
io these vertical pores can act as channels for nutrient
diffusion the making of these in 3D molds to create 3D
foams with the desired microstructure combinations of
compositional and architectural gradient. Generally the
foams formed in containers or molds will have a
thickness in the range of from about 0.25mm to about
100mm and preferably will have a thickness of from about
0.5mm to about 50mm. Thicker foams can be made but the
lyophilization cycle times may be quite long, the final
foam structures may be more difficult to control and the
residual solvent content may be higher.
As previously described the inventive process cycle for
producing biocompatible foam is significantly reduced by
performing the sublimation step above the apparent glass
transition temperature and below the solidification
temperature of the mixture (preferably just below the
solidification temperature). The combined cycle time of
(freezing + primary drying + secondary drying) is much
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faster than is described in the prior art. For example,
the combined cycle for aliphatic polyesters using
volatile solvents is generally less than 72 hours,
preferably less than 48 hours, more preferably less than
24 hours and most preferably less than 10 hours. In
fact the combined cycle can be performed with some
aliphatic polyesters in less than 3 hrs for foams of
thickness lmm or less; less than 6 hrs for foams of
thickness around 2 mm and less than 9 hrs for foams of
thickness around 3 mm. Compare this with prior art
which is typically 72 hours or greater. The residual
solvent concentrations in these foams made by this
process,will be very low. As described for aliphatic
polyesters foams made using 1,4-dioxane as a solvent the
residual concentratiorr of 1,4-dioxane was less than 10
ppm (parts per million) more preferably less than 1 ppm
and most preferably less than 100 ppb (parts per
billion).
One skilled in the art can easily visualize that such a
directionality can be created in any three-dimensions by
designing an appropriate mold and subjecting the walls
of such a mold to different temperatures if needed. The
following types of gradient structures can be made by
this invention
1. variation in the pore size and/or shape through the
thickness with a uniform composition,
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2. pores of one type and size for a certain thickness
followed by another type and size of pores, etc
3. compositional gradient with predominantly one
compostion on one side and another composition on the
other with a transition from one entity to the other
4. a thick skin comprising low porosity of low pore size
layer followed by a large pore size region
5. foams with vertical pores with a spatial
organization...these vertical pores can act as channels
for nutrient diffusion
6. the making of these in three-dimensional molds to
create three-dimensional foams with the desired
microstructure.
7. combinations of compositional and architectural
Zs gradient
Additionally, various proteins (including short chain
peptides), growth agents, chemotatic agents and
therapeutic agents (antibiotics, analgesics, anti-
inflammatories, anti-rejection (e.g. immunosuppressants)
and anticancer drugs), or ceramic particles can be added
to the foams during processing, adsorbed onto the
surface or back filled into the foams after the foams
are made. For example, the pores of the foam may be
partially or completely filled with biocompatible
resorbable synthetic polymers or biopolymers (such as
collagen or elastin) or biocompatible ceramic materials
(such as hydroxyapatite) and combinations thereof (that
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may or may not contain materials that promote tissue
growth through the device). Suitable materials include
but are not limited to autograft, allograft, or
xenograft bone, bone marrow, morphogenic proteins
(BMP's), epidermal growth factor (EGF), fibroblast
growth factor (FgF), platelet derived growth factor
(PDGF), insulin derived growth factor (IGF-I and IGF-
II), transforming growth factors (TGF-(3), vascular
endothelial growth factor (VEGF) or other osteoinductive
or osteoconductive materials known in the art.
Biopolymers could also be used as conductive or
chemotactic materials, or as delivery vehicles for
growth factors. Examples could be recombinant or animal
derived collagen or eiastin or hyaluronic acid.
is Bioactive coatings or surtace treatments could also be
attached to the surface of the materials. For example,
bioactive peptide sequences (RGD's) could be attached to
facilitate protein adsorption and subsequent cell tissue
attachment. Therapeutic agents may also be delivered
with these foams.
In another embodiment of the present invention, the
polymers and blends that are used to form the foam can
contain therapeutic agents. To form these foams, the
previously described polymer would be mixed with a
therapeutic agent prior to forming the foam or loaded
into the foam after it is formed. The variety of
different therapeutic agents that can be used in
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conjunction with the foams of the present invention is
vast. In general, therapeutic agents which may be
administered via the pharmaceutical compositions of the
invention include, without limitation: antiinfectives
such as antibiotics and antiviral agents;
chemotherapeutic agents (i.e. anticancer agents); anti-
rejection agents; analgesics and analgesic combinations;
anti-inflammatory agents; hormones such as steroids;
growth factors (bone morphogenic proteins (i.e. BMP's 1-
7), bone morphogenic-like proteins (i.e. GFD-5, GFD-7
and GFD-8), epidermal growth factor (EGF), fibroblast
growth factor (i.e. FGF 1-9), platelet derived growth
factor (PDGF), insulin like growth factor (IGF-I and
IGF-II), transforming growth factors (i.e. TGF-(3 I-III),
vascular endothelial growth factor (VEGF)); and other
naturally derived or genetically engineered proteins,
polysaccharides, glycoproteins, or lipoproteins. These
growth factors are described in The Cellular and
Molecular. Basis of Bone Formation and Repair by Vicki
Rosen and R. Scott Thies, published by R.G. Landes
Company.
Foams containing bio-active materials may be formulated
by mixing one or more therapeutic agents with the polymer
used to make the foam or with the solvent or with the
polymer-solvent mixture and foamed. Alternatively, a
therapeutic agent could be coated on to the foam
preferably with a pharmaceutically acceptable carrier.
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Any pharmaceutical carrier can be used that does not
dissolve the foam. The therapeutic agents, may be
present as a liquid, a finely divided solid, or any other
appropriate physical form. Typically, but optionally, the
matrix will include one or more additives, such as
diluents, carriers, excipients, stabilizers or the like.
The amount of therapeutic agent will depend on the
particular drug being employed and medical condition
being treated. Typically, the amount of drug represents
about 0.001 percent to about 70 percent, more typically
about 0.001 percent to about 50 percent, most typically
about 0,.001 percent to about 20 percent by weight of the
matrix. The quantity and type of polymer incorporated
into the drug delivery mat~ix will vary depending on the
release profile desired and the amount of drug employed.
Upon contact with body fluids the drug will be released.
If the drug is incorporated into the foam then as the
foam undergoes gradual degradation (mainly through
hydrolysis) the drug will be released. This can result in
prolonged delivery (over, say 1 to 5,000 hours,
preferably 2 to 800 hours) of effective amounts (say,
0.0001 mg/kg/hour to 10 mg/kg/hour) of the drug. This
dosage form can be administered as is necessary depending
on the subject being treated, the severity of the
affliction, the judgment of the prescribing physician,
and the like. Following this or similar procedures,
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those skilled in the art will be able to prepare a
variety of formulations.
The foam may also serve as a scaffold for the
engineering of tissue. The porous gradient structure
would be conducive to growth of cells. As outlined in
previous patents (Vacanti, U.S. 5,770,417), cells can be
harvested from a patient (before or during surgery to
repair the tissue) and the cells can be processed under
sterile conditions to provide a specific cell type
(i.e., pluripotent cells, stem cells or precursor cells
such as the mesenchymal stem cells described in Caplan,
U.S. 5,486,359, etc.). Suitable cell that may be
contacted or seeded into the foam scaffolds include but
are not limited to myocytes, adipocytes, fibromyoblasts,
ectodermal cell, muscle cells, osteoblast (i.e. bone
cells), chondrocyte (i.e. cartilage cells), endothelial
cells, fibroblast, pancreatic cells, hepatocyte, bile
duct cells, bone marrow cells, neural cells,
genitourinary cells (including nephritic cells) and
combinations thereof. Various cellular strategies could
be used with these scaffolds (i.e., autogenous,
allogenic, xenogeneic cells etc.). The cells could also
contain inserted DNA encoding a protein that could
stimulate the attachment, proliferation or
differentiation of tissue. The foam would be placed in
cell culture and the cells seeded onto or into the
structure. The foam would be maintained in a sterile
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environment and then implanted into the donor patient
once the cells have invaded the microstructure of the
device. The in vitro seeding of cells could provide for
a more rapid development and differentiation process for
s the tissue. It is clear that cellular differentiation
and the creation of tissue specific extracellular matrix
is critical for the tissue engineering of a functional
implant.
The option for seeding different cell types into the
different pore structures would be available to
investigators. Different cell types (i.e. stromal cells and
chondrocytes) can be cultured on different structures.
The structures can be combined after a short- period of
time and the entire structure can be placed back in cell
culture so a biphasic tissue structure can be generated
for implantation. A gradient structure would also allow
for co-cultured tissue scaffolds to be generated.
Additionally, radio-opaque markers may be added to the foams to
allow imaging after implantation. After a defined period of
in vitro development (for example 3 weeks), the tissue engineered
implant would be harvested and implanted into the
patient. If an acellular strategy is pursued, then the
sterile acellular scaffolds would be used to replace
damaged or traumatized tissue.
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The foam scaffolds of the present invention may be
sterilized using conventional sterilization process such
as radiation based sterilization (i.e. gamma-ray),
chemical based sterilization (ethylene oxide) or other
appropriate procedures. Preferably the sterilization
process will be with ethylene oxide at a temperature
between 52-55 C for a time of 8 hours or less. After
sterilization the foam scaffolds may be packaged in an
appropriate sterilize moisture resistant package for
shipment and use in hospitals and other health care
facilities.
In another embodiment of the present invention the foam
may have a fibrous fabric fused to the top or bottom
is surface. This way, surface properties of the structure
can be controlled such as porosity, permeability,
degradation rate and mechanical properties. The fibrous
fabric can be produced via an electrostatic spinning
process in which a fibrous layer can be built up on a
lyophilized foam surface. The electrostatic spinning
process is a method that has been used to make fibers.
Electrostatic spinning of many polymeric materials has
been described in the following patents and articles: US
Patent No. 4,522,709; US Patent No. 5,024,789; US Patent
No. 5,311,884; US Patent No. 5,522,879; "Nanometre
diameter fibers of polymer, produced by
electrospinning," Nanotechnology 1 (1996) 216-233;
"Structure and morphology of small diameter electrospun
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aramid fibres," Polymer Inter., 36 (1995) 195-201,
"Carbon nanofiber from polyacrylonitrile and mesophase
pitch," Journal of Advanced Materials, Vol. 3, No. 1,
(1999) 36-41. This process may also be used with the
aliphatic polyesters previously described in this
application using appropriate solvents. T'he solvents
used in the foaming process may also be used for
electrostatic spinning.
In this process, an electrical force is applied to the
polymeric solution that overcomes the surface tension of
the solution, forming a charged jet. This jet of
solution is ejected, dried and solidified onto a
grounded substrate. Fsy controlling the spir~ning
115 conditions, the resulting fibers can range from about
0.1 gm to about 20 gm and preferably will range from
about 0.3 m to about 5.0 m. The substrate surface in
this case would be a lyophilized foam. Two examples of
such a construct, with a fibrous layer on top of a foam
layer, are shown in Figures 12 and 13. These layered
structures may be made of at least one biocompatible
material and may be non-absorbable, absorbable or a
combination thereof.
The composition, thickness and porosity of the fibrous
layer may be controlled to provide the desired
mechanical and biological characteristics. For example
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the bioabsorption rate of the fibrous layer may be
selected to provide a longer or shorter bioabsorption
profile as compared to the underlying foam layer.
Additionally, fibrous layer may provide greater
s structural integrity to the composite so that mechanical
force may be applied to the fibrous side of the
structure. For example the fibrous layer could allow
the use of sutures, staples or various fixation devices
to hold the composite in place. As a general guideline
but in no way limiting the scope of the invention it is
currently preferred that the fibrous layer comprise a
layer of from about 1 micron to about 1000 microns in
thickness.
One possible application of a foam structure with a
fibrous surface layer is as a vascular graft. The
layers in such a structure would form concentric
cylinders, and the fibrous layer would provide a
decreased permeability. The lyophilized foam structure
could be optimized for cell infiltrat.ion either on the
adventitial surface by smooth muscle cells or
fibroblasts, or on the lunlinal surface by endothelial
cells. The fibrous fabric layer would serve as a
barrier to blood leakage, and would enhance the
mechanical properties of the structure. Additionally,
the fibrous layer would serve as a barrier to
multiplying smooth muscle cells and would assist in the
prevention of intimal hyperplasia.
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Another possible application of such a hybrid
foam/fabric structure is as a scaffold for breast
regeneration. The fibrous layer would provide increased
mechanical integrity, and would maintain the original
shape of the scaffold. When a biopsy is taken or when a
tumor is removed, the cavity could be filled with such a
fibrous coated foam scaffold, which may or may not be
injected with cells or bioactive agents.
Another possible application of such a foam/fabric
structure is as a scaffold for meniscal tissue
engineering. In this case, a wedge shaped implant could
be made consisting of a fibrous coating encapsulating a
1s lyophilized foam center. The cells could be injected
into the center of the implant through the fibrous
layer. This fabric surface layer would allow the
diffusion of nutrients and waste products while limiting
the migration of the cells out of the scaffold.
The following examples are illustrative of the
principles and practice of this invention, although not
limited thereto. Numerous additional embodiments within
the scope and spirit of the invention will become
apparent to those skilled in the art.
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Examples
In the examples which follow, the polymers and monomers
were characterized for chemical composition and purity
(NMR, FT-IR), thermal analysis (DSC), molecular weight
(inherent viscosity), and baseline and in vitro
mechanical properties (Instron stress/strain).
1H NMR was performed on a 300 MHz NMR using CDC13 or HFAD
(hexafluoroacetone sesqua deutrium oxide) as a solvent.
Thermal analysis of segmented polymers and monomers was
performed on a Dupont 912 Differential Scanning
Calorimeter (DSC). Inherent viscosities (I.V., dL/g) of
the polymers and copolymers were measured using a 50
bore Cannon-Ubbelhode dilution viscometer immersed in a
thermostatically coritrol2cd water bath at 25 C utilizing
chloroform or hexafluoroisopropanol (HFIP) as the
solvent at a concentration of 0.1 g/dL.
In these examples certain abbreviations are usde such as
PCL to indicate polymerized s-caprolactone, PGA to
indicate polymerized glycolide, PLA to indicate
polymerized (L)lactide. Additionally, the percentages
in front of the copolymer indicates the respective mole
percentages of each constituent.
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Example 1
Preparation of a foam with random microstructure (no
preferred architecture)
Step A. Preparing 5% wt./wt. homogeneous solution of
35/65 PCL/PGA in 1,4-Dioxane
A 5 % wt./wt. polymer solution is prepared by dissolving
1 part of 35/65 PCL/PGA with 19 parts of the solvent -
1,4-dioxane. The 35/65 PCL/PGA copolymer was made
substantially as described in Example 8. The solution is
prepared in a flask with a magnetic stir bar. For the
copolymer to dissolve completely, it is recommended that
the mixture is gently heated to 60 5 C and continuously
stirred for a minimum of 4 hours but not exceeding 8
hours. A clear homogeneous solution is then obtained by
filtering the solution through an extra coarse porosity
filter (Pyrex brand extraction thimble with fritted
Tm
disc) using dry nitrogen to help in the filtration of
this viscous solution.
Step B: Lyophilization
A laboratory scale lyophilizer - Freezemobile 6 of
Tm
VIRTIS was used in this experiment. The freeze dryer is
powered up and the shelf chamber is maintained at 20 C
under dry nitrogen for approximately 30 minutes.
Thermocouples to monitor the shelf temperature are
attached for monitoring. Carefully fill the homogeneous
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polymer solution prepared in Step A. into the molds just
before the actual start of the cycle. A glass mold was
used in this example but a mold made of any material
that is inert to 1,4-dioxane; has good heat transfer
characteristics; and has a surface that enables the easy
removal of the foam can be used. The glass mold or dish
used in this example weighed 620 grams, was optical
glass 5.5mm thick, and cylindrical with a 21cm outer
diameter and a 19.5cm inner diameter. The lip height of
the dish was 2.5cm. Next the following steps are
followed in a sequence to make a 2mm thick foam:
(i). The glass dish with the solution is carefully
placed (without tilting) on the shelf of the
lyophiiizer, -w'riicri is iliainLained at 20 C. The cycle is
started and the shelf temperature is held at 20 C for 30
minutes for thermal conditioning.
(ii). The solution is then cooled to -5 C by cooling the
shelf to -5 C.
(iii). After 60 minutes of freezing at -5 C, a vacuum is
applied to initiate primary drying of the dioxane by
sublimation. One hour of primary drying under vacuum at
-5 C is needed to remove most of the solvent. At the
end of this drying stage typically the vacuum level
reached about 50 mTorr or less.
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(iv). Next, secondary drying under a 50 mTorr vacuum or
less was done in two stages to remove the adsorbed
dioxane. In the first stage, the shelf temperature was
raised to 5 C and held at that temperature for 1 hour.
s At the end of the first stage the second stage of drying
was begun. In the second stage of drying, the shelf
temperature was raised to 20 C and held at that
temperature for 1 hour.
(v). At the end of the second stage, the lyophilizer is
brought to room temperature and the vacuum is broken
with nitrogen. The chamber is purged with dry nitrogen
for approximately 30 minutes before opening the door.
ls The steps described above are suitable for making foams
that are about 2mm thick or less. As one skilled in the
art would know, the conditions described herein are
typical and operating ranges depend on several factors
e.g.: concentration of the solution; polymer molecular
weights and compositions; volume of the solution; mold
parameters; machine variables like cooling rate, heating
rates; and the like. Figure 1 shows a SEM of a cross
section of the foam produced following the process set
forth in this example. Note the random microstructure
(not a preferred architecture) of this foam.
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Example 2
Preparation of a foam with vertical channels
This example describes the making of a 35/65 PCL/PGA
foam with vertical channels that would provide pathways
for nutrient transport and guided tissue regeneration.
We used a FTS Dura Dry Freeze dryer with computer
control and data monitoring system to make this foam.
First step in the preparation of this foam was to
generate a homogeneous solution. A 10% wt./wt.
homogeneous solution of 35/65 PCL/PGA was made in a
manner similar to that described in Example 1, Step A.
is The polymer solution was carefully filled into a dish
just before the actual start of the cycle. The dish
weighed 620 grams, was optical glass 5.5mm thick, and
cylindrical with a 21cm outer diameter and a 19.5cm
inner diameter. The lip height of the dish was 2.5cm.
Next the following steps are followed in sequence to
make a 2mm thick foam with the desired architecture:
(i). The solution filled dish was placed on the freeze
dryer shelf that was precooled to -17 C . The cycle was
started and the shelf temperature was held at -17 C for
15 minutes quenching the polymer solution.
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(ii). After 15 minutes of quenching to -17 C, a vacuum
was applied to initiate primary drying of the dioxane by
sublimation and held at 100 milliTorr for one hour.
(iii). Next, secondary drying was done at 5 C for one
hour and at 20 C for one hour. At each temperature the
vacuum level was maintained at 20 mTorr.
(iv). At the end of the second stage, the lyophilizer
was brought to room temperature and the vacuum was
broken with nitrogen. The chamber was purged with dry
nitrogen for approximately 30 minutes before opening the
door.
is Figure 2 is a SEM picture that shows a cross section of
the foam with vertical channels. These channels run
through the thickness of the foam.
Example 3
Architecturally gradient foam
This example describes the making of a foam that has a
gradient in foam morphology as shown in Figure 3 using a
10% solution of 35/65 s-caprolactone-co-glycolide. The
method used to make such a foam is similar to the
description given in Example 2 with one difference. In
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step (ii) of the lyophilization process the time for
which the solution is kept at the freezing step is 30
minutes.
Figure 3 is a scanning electron micrograph of a cross
section of this foam. Note the variation in the pore
size and pore shape through the thickness of the foam.
Example 4
Transcompositional foam
This example describes the making of a foam that has a
compositional gradient and not necessarily a
morphological gradient. Such a foam is made from
polymer solutions that have been made from physical
mixtures of two or more polymers. This example
describes a transcompositional foam made from 35/65
PCL/PGA and 40/60 PCL/PLA
Step A. Preparing a solution mixture of 35/65 PCL/PGA
and 40/60 PCL/PLA in 1,4-Dioxane
In the preferred method the two separate solutions are
first prepared (a) a 10% wt/wt polymer solution of 35/65
PCL/PGA and (b) a 10% wt/wt 40/60 PCL/PLA. Once these
solutions are prepared as described in Example 1, equal
parts of each solution was poured into one mixing flask.
The polymers used to make these solutions are described
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in Examples 8 and 9. A homogeneous solution of this
physical mixture was obtained by gently heating to 60
C and continuously stirring using a magnetic stir bar
for approximately 2 hours.
5
Step B. Lyophilization cycle
We used an FTS Dura Dry Freeze dryer with computer
control and data monitoring system to make this foam.
The first step in the preparation of such a foam was to
generate a homogeneous solution as described in Step A.
The solution was carefully filled into a dish just
before the actual start of the cycle. The cylindrical
glass dish weighed 117 grams, was optical glass 2.5mm
thick and cylindrical with a 100mm outer diameter and a
95mm inner diameter. The lip heighc of the dish was
50mm. Next the following steps were followed in
sequence to make a 25mm thick foam with the
transcompositional gradient:
(i). The solution filled dish was placed on the freeze
dryer shelf and the solution conditioned at 20 C for 30
minutes. The cycle was.started and the shelf
temperature was set to -5 C with a programmed cooling
rate of 0.5 C/min.
(ii). The solution was held at the freezing condition (-
5 C) for 5 hours.
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(iii). Vacuum was applied to initiate primary drying of
the dioxane by sublimation and held at 100 milliTorr for
hours.
5 (iv). Next, secondary drying was done at 5 C for 5 hours
and at 20 C for 10 hours. At each temperature the
vacuum level was maintained at 20 mTorr.
(v). At the end of the second stage, the lyophilizer was
brought to room temperature and the vacuum was broken
with nitrogen. The chamber was purged with dry nitrogen
for approximately 30 minutes before opening the door.
The foam has a gradient in chemical composition which is
i~ evident from a close scrutiny of the foam wall
morphology as shown in Figure 4, 5 and 6. The gradient
in the chemical composition was further supported by NMR
data as detailed below:
Foam sample produced by the above method and which was
approximately 25 mm thick was characterized for mole %
composition. The foam sample is composed of a physical
blend of PCL/PLA and PCL/PGA. Slices of the foam sample
were prepared and analyzed to confirm that the material
was a compositional gradient. The sample slices were
identified as 1) foam IA (top slice), 2) foam IB (top
middle slice), 3) foam IC (bottom middle slice), 4) foam
ID (bottom slice). The NMR sample preparation consisted
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of dissolving a 5mg of material into 300 L
hexafluoroacetone sesqua deutrium oxide (HFAD) and then
diluting with 300 L of C6D6.
1H NMR Results: Mole % Composition
Sample PLA PGA PCL
ID
Foam IA
47.2 12.4 40.5
Foam IB
12.3 51.3 36.5
Foam IC
7.7 56.5 35.8
Foam ID
7.8 56.3 35.8
The NMR results indicate tiiat the foam samples have a
gradient with respect to composition. The top layer of
the foam is high in PLA concentration (47 mole %),
whereas the bottom layer of the foam is high in PGA
concentration (56 mole %). These results suggest that
the PCL/PGA copolymer and the PCL/PLA copolymer have
differences in their phase separation behaviors during
the freezing step and formed a unique compositionally
gradient foam.
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Example 5
Transstructural foam
This example describes the making of a foam that has a
compositional and structural gradient and not
necessarily a morphological gradient. Such a foam is
made from polymer solutions that have been made by
physical mixtures of two or more polymers. This example
describes a transcompositional foam made from 35/65
PCL/PLA (as described in Example 9) and 95/5 PLA/PCL (a
random copolymer with an IV of 1.8 in HFIP measured as
described herein). Note, 35/65 PCL/PLA is a soft
elastomeric copolymer while 95/5 PLA/PCL is a relatively
stiff copolymer. The combination of the two provides a
is compositional as well as structural gradient. This foam
is made using the steps outlined in Example 4 starting
from a homogeneous 50/50 physical mixture of a 10%
wt./wt. solution of 35/65 PCL/PLA and 10% wt./wt.
Solution of 95/5 PLA/PCL in 1,4 dioxane. Such a
transcompositional foam will provide a good template for
tissue junctions such as bone-cartilage interfaces.
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Example 6
Cell culture and differentiation data
Films made from 95/5 PLA/PGA, 90/10 PGA/PLA, 95/5
PLA/PCL, 75/25 PGA/PCL and 40/60 PCL/PLA were tested.
Tissue culture polystyrene (TCPS) was used as a positive
control for all the assays. Before testing, polymer
discs were positioned at the bottom of a 24-well
ultralow cluster dish and were pre-wetted in growth
media for 20 min.
The 95/5 PLA/PGA copolymer used in this example was a
random copolymer with an IV of 1.76 as determined in
HFIP at 25 C, which is currently used in PanacrylT"
suture (Ethicon Inc., Somerville, New Jersey). The
90/10 PGA/PLA copolymer was a random copolymer with an
IV of 1.74 as determined in HFIP at 25 C, which is
currently used in VicylT"" suture (Ethicon Inc.,
Somerville, New Jersey). The 95/5 PLA/PCL polymer was
made as described in Example 10, with an IV of 2.1 as
determined in HFIP at 25 C. The 75/25 PG/PCL copolymer
is a segmented block copolymer with an IV of 1.85 and is
described in US Patent 5,133,739 this copolymer is
currently used in MonocrylT ^ sutures (Ethicon Inc.,
Somerville, New Jersey). The 40/60 PCL/PLA copolymer
used in this Example was made as described in Example 9
and had an IV of 1.44.
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Cell attachment and proliferation: Cells were seeded at
40,000/well in 24-well ultralow cluster dishes (Corning)
containing the polymers. The ultralow cluster dishes
are coated with a layer of hydrogel polymer, which
retards protein and cell adhesion to the wells. Cell
attachment to the biopolymers was determined following
24 hrs of incubation (N=3 for each polymer) . The
attached cells were released by trypsinization and the
number of cells was determined using a h.eamacytometer.
Cell proliferation was assessed by determining cell
counts at days 3 and 6 following seeding.
Differentiation assays:
Alkaline phosph.atase activity: Alkaline phosphatase
activity was determined by a colorimetric assay using p-
nitrophenol phosphate substrate (Sigma 104) and
following manufacturers instruction. Briefly, cells
were seeded on the films or meshes at a density of
40,000 cells/well and incubated for 1, 6, 14, and 21 d.
Once cells reached confluence at day 6 they were fed
with mineralization medium (growth medium supplemented
with 10rmM (3-glycerophosphate, 50 g/ml ascorbic acid).
Alkaline phosphatase activity was determined in cell
TM
homogenates (0.05% Triton X-100) at the above time
points. The quantity of protein in cell extracts was
determined by micro BCA reagent from Pierce. Primary
rat osteoblasts cultured on films and meshes were also
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stained for membrane-bound alkaline phosphatase using a
histochemical staining kit (Sigma). For all the films
and meshes three samples per group were tested.
Osteocalin ELISA: Osteocalcin secreted into the medium
by osteoblasts cultured on various films was quantified
by ELISA (Osteocalcin ELISA kit, Biomedical Technologies
Inc, Boston). Aliquots of media from the wells
containing the polymer films were lyophilized prior to
measurements of this protein by ELISA. Three samples
for each polymer were tested and the ELISA was repeated
twice.
Von Kossa staining
Three sariiples for each polymer were stained for
mineralized tissue using Von Kossa silver nitrate
staining.
Expression of alkaline phosphatase and osteocalcin mRNAs
The expression of alkaline phosphatase and osteocalcin
mRNAs in cells was assessed by semi-quantitative reverse
transcriptase polymerase chain reaction (RT-PCR) using
RNA extracted from cells cultured for 21 d on the films.
Seven days after seeding, the culture media was
replaced with mineralization media (3 mM (3-
glycerophosphate and 50 g/ml of ascorbic acid were
added). The cells were cultured for additional 2 weeks,
for a total period of 3 weeks. Total RNA was extracted
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TM
from four samples per group using a RNeasy mini kit
provided by Qiagen. The quality and amount of total RNA
was measured for each polymer group. Total RNA was
reverse transcribed to obtain cDNA using a reverse
TM
transcriptase reaction (Superscript II, Gibco). The
cDNAs for osteocalcin, alkaline phosphatase, and
Glyceraldehyde-3-phosphate-dehydrogenase (GAPDH) were
amplified using a PCR protocol described previously
(GIBCO BRL manufacturers instruction). The primer
sequences (Table I) for osteocalcin, alkaline
TM
phosphatase, and GAPDH were obtained using the FASTA
program (Genetic Computer Group, Madison, WI).
Preliminary studies were also conducted to optimize the
number of PCR cycles for each primer (Table II), and to
is determine the range of RNA, which exhibits
proportionality to cDNA. The PCR products were
electrophoreses on 1% (wt) agarose gels containing
ethidium bromide. The gels were photographed under UV
light and were evaluated by densitometry for the
expression of osteocalcin and alkaline phosphatase mRNAs
relative to GAPDH.
Statistical Anlysis,
Analysis of variance (A.NOVA) with Tukey post hoc ,
comparisons was used to assess levels of significance
for all the assays.
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Table I. Primers used in RT-PCR
Gene Specie Forward primer Reverse primer Size
s (bp)
Alkalin Rat 5' 5' 379
e ATCGCCTATCAGCTAAT GCAAGAAGAAGCCTTT
phospha GCAC GGG
tase
Osteoca Rat/Hu 5'CAACCCCAATTGTGA 5' 339
lcin man CGAGC TGGTGCGATCCATCAC
AGAG
GAPDH Mouse/ 5'ACCACAGTCCATGCC 5'TCCACCACCCTGTT 452
Human/ ATCAC GCTGTA
Rat
Table II PCR optimization cycles
Gene cDNA ( l) Cycles
Alkaline 1 25
phosphatase
Osteocalcin 1 35
GAPDH 1 23
Results
Cell attachment and proliferation on bioresorbable
polymers: No observable difference in cell morphology
was evident between the various polymer films and as
compared to TCPS. Cell attachment to the various
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biopolymer films was equivalent to TCPS following 24 h
of incubation. At day 3, cells proliferated well on all
films with the exception of 40/60 PCL/PLA, where
proliferation was 60% relative to TCPS. Furthermore,
95/5 PLA/PGA and 90/10 PGA/PLA films supported a
significantly (p<0.05) higher degree of cell
proliferation compared to TCPS and 40/60 PCL/PLA (Fig.
7A) .
Differentiation assay:
Alkaline phosphatase enzyme activity: The profile for
alkaline phosphatase activity expressed by osteoblasts
cultured on 95/5 PLA/PGA, 90/10 PGA/PLA and 95/5 PLA/PCL
films was similar to the profile observed ori TCPS.
1.5 Alkaline phosphatase specific activiti`s were
significantly (p<0.05) elevated for osteoblasts cultured
on 40/60 PCL/PLA and 75/25 PGA/PCL films at days 14 and
21, respectively, compared to other films and TCPS (Fig.
7B)
Expression of alkaline phosphatase and osteocalcin mRNA:
The expression of mRNAs for alkaline phosphatase,
osteocalcin, and GAPDH for osteoblasts cultured on the
95/5 PLA /PGA, 40/60 PLA/ PCL, 95/5 PLA/ PCL films, and
TCPS were evaluated by densitometry. The results are
depicted in Fig. 7C. It should be noted that the data
in Fig. 7B is at best semi-quantitative. Nevertheless,
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the data suggests that 40/60 PCL/ PLA film supported
significantly (p<0.05) higher levels of osteocalcin
expression compared to TCPS. The rest of the polymer
surfaces were equivalent to TCPS for both osteocalcin
and AP mRNAs expression.
Conclusions
No major differences were observed with respect to cell
attachment and proliferation between the different
bioresorbable films or meshes tested following 6 days of
incubation. Furthermore, the results indicate that
differences between these materials were more obvious
with respect to their differentiation characteristics.
1.5 Cells cultured on 40/60 PCL/PLA film showed enhanced
alkaline phosphatase activity and osteocalcin mRNA
expression compared to other films and TCPS following 14
arid 21 days of incubation, respectively.
References that may be referred to for a more complete
understanding of this technique"s include, M. A. Aronow,
L.C. Gerstenfeld, T.A. Owen, M.S. Tassinari, G.S. Stein
and J.B. Lian: "Factors that promote progressive
development of the osteoblast phenotype in cultured
fetal rat calvaria cells: Journal of Cellular
Physiology, 143: 213-221 (1990) and Stein, G. S., Lian,
J. B., and Owen, t. A. "Relationship of cell growth to
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the regulation of tissue-specific gene expression during
osteoblast differentiation" FASEB, 4, 3111-3123 (1990).
Example 7
In vivo Study of Foam Blend in Swine Dermal Wound
Healing Model
This example describes the results of implanting a imm,
0.5mm thickness foam tissue scaffolding in a swine full
thickness excisional wound rnodel. The foam tissue
scaffold was made from a blend of 40/60 c-caprolactone-
co-lactide made as described in Example 8 and 35/65 E-
caprolactone-co-glycolide described in Example 9. These
polymers were blended together and formed into lmm and
0.5 mm foams substantially as described in Example 3
(except that the cooling rate was 2.5 C per minute and it
was cooled only to -5 C). Scanning electron micrographs
of a 0.5mm foam are presented in Figures 9A, 9B and 9C.
The two thickness (0.5mm and imm) of foams were then
tested in the wound excisional model with and without
PDGF being provided. The resulting four different
samples were then evaluated.
A blinded histologic evaluation was performed on 48 full
thickness excisional wounds from four pigs (12 sites per
animal) explanted at 8 days following wounding. The
assessment was performed on H&E stained slides. During
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the histologic assessment, the following parameters were
ranked/evaluated across the specimen set 1) cellular
invasion of the matrix qualitative and quantitative
assessments 2) infiltration of polymorphonuclear
leukoctyes (PMNs) into the contact zone (ventral
surface) of the matrix, 3) inflammation in the
granulation tissue bed below (ventral to) the matrix, 4)
reaction of the epidermis to the matrix, and 5) degree
of fragmentation of the matrix.
Animal Husbandry:
The pigs were housed individually in cages (with a
minimum floor area of 10-sq. ft.) and given
identification. All pigs were assigned an individual
i5 animal number. A tag was placed on each individual
animal cage listing the animal number, species/strain,
surgical date, surgical technique and duration of the
experiment and date of euthanasia. Each animal was
clearly marked with an animal number on the base of the
neck using a permanent marker.
The animal rooms were maintained at the range of 40 to
70% R.H. and 15 to 24 C (59.0 to 75.2 F). The animals
were fed with a standard pig chow once per day, but were
fasted overnight prior to any experimental procedure
requiring anesthesia. Water was available ad libitum.
A daily light:dark cycle of 12:12 hours was adopted.
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Anesthesia:
On the initial day of the study, days of evaluation and
the day of necropsy, the animals were restrained and
anesthetized with either an intramuscular injection of
Tiletamine HC1 plus Zolazepam HC1 (Telazol'~', Fort Dodge
Animal Health, Fort Dodge, Iowa 4 mg/ml) and Xylazine
(Rompun'% Bayer Corporation, Agriculture Division, Animal
Health, Shawnee Mission, Kansas, 4mg/ml) or Isoflurane
(AErrane~ Fort Dodge Animal Health, Fort Dodge, Iowa)
inhalatory anesthesia (5% vol.) administered via a nose
cone. When the animal was in the surgical suite, it was
maintained on Isoflurane (AErrane) inhalatory anesthesia
(2% vol.) administered via a nose cone. Food was
available after recovery from each procedure.
Preparation of the Surgical Site:
One day prior to the surgical procedure, body weights
were measured and the dcrsal region of four pigs were
clipped with an electric clipper equipped with a#40
surgical shaving blade. The shaved skin was then re-
shaved closely with shaving cream and a razor and then
rinsed. The shaved skin and entire animal (excluding
the head) was then scrubbed with a surgical scrub brush-
sponge with PCMX cleansing solution (Pharmaseal'~' Scrub
Care(E Baxter Healthcare Corporation, Pharmaseal Division,
Valencia, California) and then with HIBICLENSc'
chlorhexidine gluconate (available from COE
Laboratories, Incorporated, Chicago, Illinois). The
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animal was wiped dry with a sterile towel. Sterile NU-
GAUZE* gauze (from Johnson & Johnson Medical
Incorporated, Arlington, Texas) was placed over the
dorsal surface of each animal and secured with
WATERPROOF* tape (available from Johnson & Johnson
Medical Incorporated, Arlington, Texas). The entire
torso region of the animal was then wrapped with
SpandageTM elastic stretch bandage (available from Medi-
Tech International Corporation, Brooklyn, New York) to
maintain a clean surface overnight.
On the day of surgery, immediately prior to delivering
the animal to the surgical suite, the dorsal skin was
again scrubbed using a surgical.scrub brush-sponge with
i5 PCMX cleansing solution (Pharmaseal~ Scrub Carec), rinsed
and wiped dry using a sterile towel, as performed on the
previous day. The animals were placed prone on the
surgical table and wiped with 70% alcohol and dried with
sterile gauze. Using a sterile surgical marker
(availabe from Codman a division of Johnson & Johnson
Professional Incorporated, Raynham, Massachusetts) and
an acetate template, marks were made on the dorsal skin
according to the desired placement of each full-
thickness wound.
Surgical Procedure:
Following anesthesia, under sterile conditions, twelve
(12) full-thickness excisions (1.5 x 1.5 cm) per animal
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were made in two rows parallel to the spinal column on
the left and right dorsal regions using a scalpel blade.
A pair of scissors and/or scalpel blade was used to aid
in the removal of skin and subcutaneous tissue.
Bleeding was controlled by use of a sponge tamponade.
Sufficient space was left between wounds to avoid wound-
to-wound interference. The excised tissue was measured
for thickness using a digital caliper.
Application of the Treatment and Dressing:
Each wound was submitted to a prepared, coded treatment
regimen (study participants were blinded to all
treatments). The primary dressing consisting of the
sterile individual test article (1.5 x 1.5 cm soaked in
sterile saline for 24 hours) was placed into the wound
deficit in a predetermined scheme. The secondary
dressing, a non-adherent, saline soaked, square of
RELEASE* dressing (manufactured by Johnson & Johnson
Medical Incorporated, Arlington, Texas) was placed on
top of the test article. A layer of BIOCLUSIVE*
dressing (available from Johnson & Johnson Medical
Incorporated, Arlington, Texas) was sealed over the
wounds to keep the wound moist and the dressing in
place. Strips of RestonTM M Medical-Surgical Division,
St. Paul, Minnesota) polyurethane self-adhering foam were
placed between the wounds to avoid cross-contamination
due to wound fluid leakage, and to protect the wounds
from damage and the dressing from displacement. A layer
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of NU-GAUZE* gauze was placed on top of the BIOCLUSIVE*
dressing and RestonTM foam, and was secured with
WATERPROOF* tape to protect the dressings. The animals
were then dressed with Spandage" elastic riet to help
keep the dressings in place.
The secondary dressings were removed and replaced daily
with a fresh piece of saline soaked RELEASE* secondary
dressing. The primary dressings (test articles) were
not disturbed unless the unit was displaced or pushed
out of the wound deficit.
POST-OPERATIVE CARE AND CLINICAL OBSERVATIONS:
After performing the procedures under anesthesia, the
animals were returned to their cages and allowed to
recover. The animals were given analgesics
(buprenorphine hydrochloride [Buprenex 'In"jectable, 0.01
mg/kg, im] sold by Reckitt & Colman Products, Hull,
England) immediately post-surgery and the following day.
After recovering from anesthesia, the pigs were
observed for behavioral signs of discomfort or pain. No
signs of pain were observed.
Each pig was observed twice daily after the day of
surgery to determine its health status on the basis of
general attitude and appearance, food consumption, fecal
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and urinary excretion and presence of abnormal
discharges.
EUTHANASIA:
At the end of the study (8 days post-wounding), each
animal was euthanized under anesthesia, with an
intravenous injection of (1 ml/10 pounds body weight)
SocumbTM pentobarbital sodium and phenytoin sodium
euthanasia solution (sold by The Butler Company,
Columbus, Ohio) via the marginal ear vein. Following
euthanasia, the animals were observed to ensure that
respiratory function had ceased and there was no
palpabl,e cardiac function. A'stethoscope facilitated
the assessment for the lack of cardiac function.
TISSUE HARVESTING:
Immediately following euthanasia, each wound, together
with the underlying fat and a small portion of
surrounding skin was excised. The tissue was placed in
10% neutral buffered formalin.
EVALUATIONS:
Visual Wound Assessment:
General observations were recorded for days 1-3,
including displacement, wound reaction and physical
characteristics of the scaffold. Detailed clinical
evaluations were performed on days 4 - 8 post-wounding.
Assessments were recorded as to the presence/absence
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(yes = 1/no = 0) and/or degree (given a score) of the
following parameters:
Dressing Conditions: air exposed, displacement of test
article, channeling, communication and moisture content
of the RELEASE* secondary dressing(scored as: 4=moist,
3=moist/dry, 2=dry/moist, 1=dry).
Wound Bed Conditions: moisture content of test article
(scored as: 4=moist, 3=moist/dry, 2=dry/moist, 1=dry),
inflammation (scored as: 3=severe, 2=moderate, 1=
slight, 0=none), reinjury (scored as: 3=severe,
2=moderate, 1= slight, 0=none), clots, folliculitis,
infection, level of test article (scored as: 4=super
raised, 3=raised, 2=even, 1=depressed), fibrin (scored
as: 3=severe, 2=moderate, 1= slight, 0=none), and
erythema. Color of the test article was also observed.
TISSUE PROCESSING:
Excised tissue samples were taken at day eight. The
entire wound was harvested and placed into 10% neutral
buffered formalin. The tissue was prepared for frozen
sections. The tissue was trimmed and mounted onto the
object holder with Tissue-Tek~ OCT Compound (sold by
Sakura Finetechnical Company, Limited, Tokyo, Japan) and
quickly frozen. The specimens were sectioned on the
cryostat at 10 m and stained with a frozen H&E stain.
HISTOLOGICAL ASSESSMENTS (Day 8 post-wounding):
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Histological evaluations for granulation tissue (area
and length) and epithelialization were assessed using
H&E stained specimens using a magnification of 20-40X.
Granulation tissue height was determined by dividing the
area by the length.
Histopathological evaluation of the tissue samples was
assessed using the H&E stained specimens, they were
first assessed under 100x to 400x magnification.
RESULTS
There was cellular invasion into the interstices of the
matrix in the majority of all test sites. In the
majority of sites this invasion was true tissue ingrowth
is comprised of varying populations of fibroblasts,
macrophages, macrophage giant cells, and endothelial-
like cells, there also appeared to be capillary
formation. Significant formation of dense fibrous
connective tissue layer dorsal to the matrices
essentially embedding the matrices in the tissue, was
seen at several sites for the 0.5mm foams with and
without PDGF. The lmm matrices were either at the
surface of the tissue bed or sloughed. Macrophage giant
cell formation seemed to be greater in the 0.5mm versus
the lmm foam scaffolds. In sites where the lmm foam was
being sloughed or partially separated from the
underlying granulation tissue there was death of the
invading cells forming masses of pyknotic cell debris.
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Complete incorporation of the matrix into the
granulation tissue bed was seen at several. sites for the
0.5mm foam scaffoldings. Figures 10 and 11 illustrate
the incorporation of these matrices into the granulation
.s tissue bed. Figure 10 is a dark filed 40X
pictomicrograph of a trichrome stained tissue sample.
Figure 11 is a 100X composite photomicrograph of a
trichrome stained sample illustrating the cellular
invasion of a foam containing PDGF. Complete
lo incorporation of the matrices into the granulation
tissue bed is evident in both pictures. The dense
fibrous tissue above the foam scaffolding is evident in
both pictures. These results indicate the 0.5mm foams
will provide a suitable substrate for the growth of
is epidermal tissue.
Example 8
Synthesis of a Random Poly(s-caprolactone-co-glycolide)
A random copolymer of E-caprolactone-glycolide with a
35/65 molar composition was synthesized by ring opening
polymerization reaction. The method of synthesis was
essentially the method described in U.S. Patent
5,468,253 in Example 6,The amount of diethylene glycol
initiator added was adjusted to 1.15 mmole/mole of
monomer to obtain the following characteristics of the
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dried polymer: The inherent viscosity (I.V.) of the
copolymer was 1.59 dL/g in hexafluoroisopropanol at 25 C.
The molar ratio of PCL/PGA was found to be 35.5/64.5 by
proton NMR with about 0.5% residual monomer. The glass
transition (Tg) and the melting points (Tm) of the
copolymer were found to be -1 C, 60 C and 126 C
respectively, by DSC.
Example 9
Synthesis of 40:60 Poly(s-caprolactone-co-L-lactide) by
Sequential Addition
In the glove box, 100 L (33 mol) of a 0.33 M stannous
octoate solution in toluene, 115 L (1.2 mmol) of
is diethylene glycol, 24.6 grams (170 mmol) of L-lactide,
and 45.7 grams (400 mmol) of E;-caprolactone were
transferred into a silanized, flame dried, two neck, 250
mL round bottom flask equipped with a stainless steel
mechanical stirrer and a nitrogen gas blanket. The
reaction flask was placed in an oil bath already set at
190 C and held there. Meanwhile, in the glove box, 62.0
grams (430 mmol) L-lactide were transferred into a flame
dried, pressure equalizing addition funnel. The funnel
was wrapped with heat tape and attached to the second
neck of the reaction flask. After 6 hours at 190 C, the
molten L-lactide was added to the reaction flask over 5
minutes. The reaction was continued overnight for a
total reaction time of 24 hours at 190 C. The reaction
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was allowed to cool to room temperature overnight. The
copolymer was isolated from the reaction flask by
freezing in liquid nitrogen and breaking the glass. Any
remaining glass fragments were removed from the copolymer
s using a bench grinder. The copolymer was again frozen
with liquid nitrogen and broken off the mechanical
stirring paddle. The copolymer was ground into a tared
glass jar using a Wiley Mill and allowed to warm to room
temperature in a vacuum oven overnight. 103.13 grams of
40:60 poly(s-caprolactone-co-L-lactide) were added to a
tared aluminum pan and then devolitilized under vacuum at
110 C for 54 hours. 98.7 grams (95.7% by weight) of
copolymer were recovered after devolitilization. The
inherent viscosity was measured and found to be 1.1 dL/g
in CHC13 at 25 C (c = 0.1 g/ciL) . FTIR (cast fiim from
CHC13 onto KBr window, cm-l): 2993, 2944, 2868, 1759,
1456, 1383, 1362, 1184, 1132, 1094, 870, and 756. 1H NMR
(400MHz, HFAD/Benzene, ppm): d 1.25, 2 broad lines (e) ;
1.35, 2 lines (f) ; 1.42, 3 lines; 1.55, 2 lines; 2.22, 3
lines ; 2.35, 4 broad lines; 4.01, 3 lines; 4.05, 3
lines; 4.2, quartet; 5.05, 3 broad lines; 5.15, 4 lines.
Polymer composition by 'H NMR: 41.8% PCL, 57.5% PLA, 0.8%
L-lactide, <0.1% e-caprolactone. DSC (20 C/min, first
heat) : Tm = 154.8 C, OHm = 18.3 J/g. GPC (molecular
weights determined in THF using poly(methyl methacrylate)
standards, daltons) : Mu, = 160,000, Mn = 101,000, PDI =
1.6.
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Example 10
Synthesis of 95/5 PLA/PCL Copolymer
s In the glove box, 170 L (1.8 mmol) of diethylene
glycol, 350 L (115 mol) of a 0.33 M stannous octoate
solution in toluene, 17.1 grams (150 mmol) of E-
caprolactone, and 410.4 grams (2.85 mol) of L-lactide
were placed into a silanized, flame dried, 1000 mL round
bottom equipped with a stainless steel mechanical
stirrer and vacuum take off connector in order to
maintain a dry nitrogen gas blanket. The reaction flask
was placed in an oil bath already heated to 185 C and
then held there for 3 hours. The flask was removed from
the oil bath and allowed to cool down to room
temperature. The polymer was isolated by wrapping the
flask with aluminum foil, freezing it in liquid
nitrogen, and then grinding away any adhered glass to
the polymer. The copolymer was then ground in a Wiley
mill. The ground polymer was vacuum dried at 80 C for 24
hours. 302 grams of copolymer were collected. The
inherent viscosity was 2.1 dL/g in chloroform [25 C,
c=0.1 g/dL]. The copolymer composition was measured by
proton NMR spectroscopy and found to be 97.2 mole
percent PLA and 2.8 mole percent PCL. No residual
monomer was detected.
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Example 11
Synthesis of 60/40 PLA/PCL Hybrid foam/microfibrous
fabric structure
Step A. Preparing 14 % wt./wt. Homogenous solution of
60/40 PLA/PCL in trichloroethane
A 14 % wt./wt. Polymer solution is prepared by
dissolving 14 parts 60/40 PLA/PCL (I.V. = 1.34 dl/g)
with 86 parts of the solvent trichloroethane (TCE). The
solution is prepared in a flask with a magnetic stir
bar. For the copolymer to dissolve completely, it is
recommended that the mixture stir overnight at 60
degrees, C .
Step B. Electrostatic spinning
The electrostatic spinner was used for this experiment.
Spellman High Voltage DC Supply (Model No.: RHR30PN30,
Spellman High Voltage Electronics Corporation,
Hauppauge, NY, USA) was used as high voltage source.
Applied voltage and the speed of mandrel were controlled
by the Labview computer software. Distance between the
spinneret was mechanically controlled..
A flat sheet of lyophilized 60/40 PLA/PCL foam, prepared
as described in Example 1, was rolled intc> a cylinder.
The ends were secured together with several drops of
trichloroethane (TCE), the solvent used iri spinning. The
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foam tube was mounted onto a rotating conductive mandrel
that was grounded. The ends of the mandrel not covered
by the foam substrate were masked with an insulating
tape to prevent the attraction of the microfibers to the
ends. The solution was placed into a spinneret and high
voltage was applied to the polymer solution. This
experiment was performed at ambient temperature and
humidity.
The operating conditions during spinning were as
follows:
Mandrel voltage 16,000 V
Mandrel speed 100 rpm
Spinneret to mandrel distance 10 cm
ib Temperature room temperature
Humidity ambient humidity
A layer of approximately 200 um in thickness was
deposited on the outer surface of the tube
Example 12
Chondrocytes cultured in an encapsulated hybrid
foam/fabric structure demonstrating the limitation of
cell migration
Step A. Preparation of hybrid 60/40 PLA/PCL
foam/microfibrous fabric scaffolds
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Lyophilized foams made from 60/40 PLA/PCL as described
in Example 1 were used as substrates during the
electrostatic spinning of 60/40 PLA/PCL in
trichloroethane, as described in detail in Example 11.
Step B. Chrondrocyte seeding into the hybrid 60/40
PLA/PCL foam/microfibrous fabric scaffold
Chondrocytes isolated from bovine shoulders were
cultured in Dulbecco's modified Eagle medium (high
glucose) supplemented with 10% fetal calf serum, 10 mM
HEPES, 0.1 mM nonessential amino acids, 20 ug/ml
streptomycin, and 0.25 ug/ml amphotericin B.
3-D TransinigraLion Assay:
This assay is based on cell-populated contracted
collagen lattice with a biodegradable polymer scaffold
implanted at the center of the collagen gel. The dermal
equivalents (collagen lattice) were fabricated from a
mixture of the following: 8 ml of chondrocyte media, 2
ml of neutralizing medium (DMEM/10% FBS containing 0.1 N
NaOH, prepared prior to use), 4 ml of rat tail type I
collagen (3.99 mg/ ml) obtained from Collaborative
Biomedical Products, and 2 ml of chondrocyte suspension
in chondrocyte medium. The above cell/collagen mixture
was distributed (2 ml) to each well of a 24-well
hydrogel-coated plate (Costar, Cat # 3473). The final
cell concentration was 6xl06 cells/ml and the collagen
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concentration was 1 mg/ml. The collagen gels was
allowed to polymerize at 37 C for 1 h. Following gel
polymerization, 1.5 ml of chondrocyte growth medium was
applied into each well. The medium was changed every
other day. After 7 days of contraction, wounds at 5 mm
in diameter were made throughout the thickness of the
collagen lattice using a disposable 5 mm biopsy punch.
Tested scaffolds, approximately 5 mm in diameter and 2
mm thick, supplied in a wet form, were implanted into a
center of the wounded collagen lattice. To assure that
the scaffold would not be pushed out from the wound bed
during contraction of the collagen lattice, 50 l of
acellular collagen was placed on the top of each
construct. Constructs were cultivated in chondrocyte
media with medium being changed in a 2-day interval.
The contracted gels containing the scaffold were
cultured either statically in ultra low cluster dishes
or in the bioreactor and collected after 3 weeks.
Step C. Cell characterization within the scaffolds
Histology was performed on the scaffolds invaded by
cells. Scaffolds were fixed in 10% buffered formalin
and were either embedded in paraffin and sectioned
(hybrid foam/microfibrous fabric scaffolds) or
cryosectioned (control foam scaffolds). Sections were
stained with Hematoxylin/eosin (H/E, cell number and
morphology), Safranin O(SO; sulfated GAGs) and
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Trichrome (collagen). Quantitation of cell invasion
into these scaffolds was determined by image analysis.
Analysis of Variance with Tukey post hoc tests were
performed on the data.
Experimental Results
Quantitative evaluation of H/E sections of constructs
cultured for 3 weeks revealed that chondrocytes invaded
both scaffolds. Cell invasion into the hybrid
foam/microfibrous fabric scaffolds, cultured in the
bioreactor, was significantly higher (P<0.05) than into
40/60 PCL/PLA foam scaffolds. Also in the statically
maintained cultures the cell invasion into the hybrid
ls foam/microfibrous fabric scaffolds was significantly
(P<0.05) higher than into 40/60 PCL/PLA foam scaffolds.
Cell invasion 40/60 PCL/PLA Hybrid
cells/mm2 foam scaffolds foam/microfibrous
(3 weeks) fabric scaffolds
Static Cell 50 80
Culture
Bioreactor 140 200
Cell Culture
Hybrid foam/microfibrous fabric scaffolds exhibited the
highest cell density. We hypothesize that cell-cell
interactions, presumably higher in the case of hybrid
foam/microfibrous fabric scaffolds as compared to the
other scaffold, may have contributed to preferential
chondrocyte proliferation and differentiated functions
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on hybrid foam/microfibrous fabric scaffolds. The cell-
cell interactions are postulated to play a critical role
in the maintenance of chondrocyte phenotype.
Chondrocytes are known to dedifferentiate when expanded
in cell monolayer. When cultured in monolayer at high
cell density chondrocytes maintain their phenotype as
indicated by the expression of type II collagen and
aggrecan.
By 6 weeks, 40/60 PCL/PLA foam scaffolds, showed
cartilage-like morphology/properties localized mainly
within the capsule around the construct. In contrast, in
hybrid foam/microfibrous fabric scaffolds,the capsule
was very thin and the cell morphology within the
constructs was cartilage-like and a more unifo.Lul
distribution of cells was observed.
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