Devices formed of or including biocompatible polyhydroxyalkanoates are provided with controlled degradation rates, preferably less than one year under physiological conditions. Preferred devices include sutures, suture fasteners, meniscus repair devices, rivets, tacks, staples, screws (including interference screws), bone plates and bone plating systems, surgical mesh, repair patches, slings, cardiovascular patches, orthopedic pins (including bone filling augmentation material), adhesion barriers, stents, guided tissue repair/regeneration devices, articular cartilage repair devices, nerve guides, tendon repair devices, atrial septal defect repair devices, pericardial patches, bulking and filling agents, vein valves, bone marrow scaffolds, meniscus regeneration devices, ligament and tendon grafts, ocular cell implants, spinal fusion cages, skin substitutes, dural substitutes, bone graft substitutes, bone dowels, wound dressings, and hemostats. The polyhydroxyalkanoates can contain additives, be formed of mixtures of monomers or include pendant groups or modifications in their backbones, or can be chemically modified, all to alter the degradation rates. The polyhydroxyalkanoate compositions also provide favorable mechanical properties, biocompatibility, and degradation times within desirable time frames under physiological conditions.

Medical devices and applications of polyhydroxyalkanoate polymers

Biocompatible polyhydroxyalkanoate compositions with controlled degradation rates have been developed. In one embodiment, the polyhydroxyalkanoates contain additives to alter the degradation rates. In another embodiment, the polyhydroxyalkanoates are formed of mixtures of monomers or include pendant groups or modifications in their backbones to alter their degradation rates. In still another embodiment, the polyhydroxyalkanoates are chemically modified. Methods for manufacturing the devices which increase porosity or exposed surface area can be used to alter degradability. For example, as demonstrated by the examples, porous polyhydroxyalkanoates can be made using methods that creates pores, voids, or interstitial spacing, such as an emulsion or spray drying technique, or which incorporate leachable or lyophilizable particles within the polymer. Examples describe poly(4HB) compositions including foams, coatings, meshes, and microparticles. As demonstrated by the examples, these polyhydroxyalkanoate compositions have extremely favorable mechanical properties, as well as are biocompatible and degrade within desirable time frames under physioogical conditions. These polyhydroxyalkanoate materials provide a wider range of polyhydroxyalkanoate degradation rates than are currently available. Methods for processing these materials, particularly for therapeutic, prophylactic or diagnostic applications, or into devices which can be implanted or injected, are also described.

Polyhydroxyalkanoate compositions having controlled degradation rates

Ring-opening polymerization (ROP) is a powerful synthetic methodology for the chemical synthesis of technologically important biodegradable aliphatic polyesters from cyclic esters or lactones. However, the bioderived five-membered γ-butyrolactone (γ-BL) is commonly referred as ‘non-polymerizable’ because of its low strain energy. The chemical synthesis of poly(γ-butyrolactone) (PγBL) through the ROP process has been realized only under ultrahigh pressure (20,000 atm, 160 °C) and only produces oligomers. Here we report that the ROP of γ-BL can, with a suitable catalyst, proceed smoothly to high conversions (90%) under ambient pressure to produce PγBL materials with a number-average molecular weight up to 30 kg mol–1 and with controlled linear and/or cyclic topologies. Remarkably, both linear and cyclic PγBLs can be recycled back into the monomer in quantitative yield by simply heating the bulk materials at 220 °C (linear polymer) or 300 °C (cyclic polymer) for one hour, which thereby demonstrates the complete recyclability of PγBL. Bio-derived γ-butyrolactone (γ-BL) is commonly referred to as ‘non-polymerizable’ due to its low strain energy. Now it has been shown that ring-opening polymerization of γ-BL can in fact proceed to high conversions under ambient pressure with a suitable catalyst, producing high-molecular-weight polymers with controlled topologies and complete recyclability.

Completely recyclable biopolymers with linear and cyclic topologies via ring-opening polymerization of γ-butyrolactone

Polyesters are currently synthesized by a step-growth mechanism from a mixture of a diol and a diacid (or a diacid derivative), or from a hydroxy-acid when available. Ring-opening polymerization (ROP) of lactones and related compounds is an alternative method for the synthesis of aliphatic polyesters. Comparison of these two mechanisms is clearly in favor of the polyaddition process. The drawbacks of polycondensation are well known:high temperatures and long reaction times are required to produce high-molecular-weight chains. Even though conversion of the hydroxyl and acid group is close to completion, any departure from the reaction stoichiometry has a very detrimental effect on the chain length.

F. Korte

Papers

Hochdruckreaktionen. II. Die polymerisation von γ‐Butyrolacton und δ‐Valerolactam bei hohen drücken