Porous material and method for fabricating same

Abstract

A composite structure comprising a first porous portion comprising a plurality of interconnected pores and a second solid portion having a first surface, said first surface secured to said first portion wherein said first and second portions are fabricated from a polymer material. The material may be suitable for implant, illustratively vertebral or spinal implants, comprising a rigid biocompatible polymer such as PEEK comprising a plurality of interconnected pores. The polymer illustratively has a porosity of between 50% and 85% by volume and in a particular embodiment is able to withstand pressures of up to 20 MPa. The porous PEEK material may also have a minimum thickness in any dimension of one (1) inch.

1 . A composite structure comprising:
 a first porous portion comprising a plurality of interconnected pores;   a second solid portion having a first surface, said first surface secured to said first portion;   wherein said first and second portions are fabricated from a polymer material.   
     
     
         2 . The structure of  claim 1 , wherein said composite material is suitable for implantation and said first portion is fabricated from a first biocompatible polymer and said second portion is fabricated from a second biocompatible polymer. 
     
     
         3 . The structure of  claim 2 , wherein said first biocompatible polymer is PEEK. 
     
     
         4 . The structure of  claim 2 , wherein said second biocompatible polymer is PEEK Carbon Prepreg. 
     
     
         5 . The structure of  claim 1 , wherein said composite material is suitable for implantation and said first portion and said second portion are both fabricated from a biocompatible polymer. 
     
     
         6 . The structure of  claim 1 , wherein said second solid portion has a second surface and further comprising a second porous portion secured to said second surface. 
     
     
         7 . The structure of  claim 1 , wherein said second solid portion is fabricated from a material the same as said first and second portions. 
     
     
         8 . The structure of  claim 1 , wherein said first porous portion has a porosity of between 50% and 85% by volume. 
     
     
         9 . The structure of  claim 1 , wherein said interconnected pores have a diameter of between about 300 and about 710 microns. 
     
     
         10 . The structure of  claim 1 , wherein said structure is able to withstand pressures of greater than about 20 MPa. 
     
     
         11 . The structure of  claim 1 , wherein said structure has a thickness of greater than one (1) inch in any dimension.