Fracture fixation systems

Abstract

Systems and methods for bone fracture repair are disclosed. One system includes a biocompatible putty that may be packed about a bone fracture to provide full load-bearing capabilities within days. The disclosed putties create an osteoconductive scaffold for bone regeneration and degrade over time to harmless resorbable byproducts.

1 .- 16 . (canceled) 
     
     
         17 . A hardenable and moldable material for orthopedic implantation and reconstruction, the material comprising:
 a resorbable polymer resin; and   a first filler having a mean particle size between about 1 μm and about 15 μm.   
     
     
         18 . The material of  claim 17 , wherein the resorbable polymer resin is a polyurethane resin. 
     
     
         19 . The material of  claim 18 , wherein the polyurethane resin is a two component material. 
     
     
         20 . The material of  claim 17 , wherein the resorbable polymer resin is a two-phase polymer system in which the first and second phases degrade at different rates. 
     
     
         21 . The material of  claim 17 , further comprising one or more catalysts to control the setting time of the resin. 
     
     
         22 . The material of  claim 17 , wherein the first filler is hydroxyapatite. 
     
     
         23 . The material of  claim 17 , further comprising a pore-forming agent that increases the porosity of the material. 
     
     
         24 . The material of  claim 23 , wherein the pore-forming agent comprises at least one of a porogen and a blowing-agent. 
     
     
         25 . The material of  claim 23 , wherein the pore-forming agent comprises at least one additional filler. 
     
     
         26 . The material of  claim 25 , wherein the at least one additional filler is present in an amount greater than the first filler. 
     
     
         27 . The material of  claim 25 , wherein the at least one additional filler comprises a second filler having a mean particle size between about 400 μm and about 4800 μm. 
     
     
         28 . The material of  claim 25 , wherein the pore-forming agent comprises a second filler and a third filler. 
     
     
         29 . The material of  claim 28 , wherein the second and third fillers comprise at least one material selected from the group consisting of degradable PU, PLA, PGA, PCL or co-polymers thereof, hydroxyapatite (HA), calcium phosphates, orthophosphates, monocalcium phosphates, dicalcium phosphates, tricalcium phosphates, whitlockite, tetracalcium phosphates, and amorphous calcium phosphates. 
     
     
         30 . A kit for an orthopedic implant comprising:
 a resorbable polymer resin;   a first filler having a mean particle size between about 1 μm and about 15 μm, wherein mixing the first filler with the resin forms a hardenable and moldable putty.   
     
     
         31 . The kit of  claim 30 , wherein the resorbable polymer resin is a polyurethane resin. 
     
     
         32 . The kit of  claim 31 , wherein the polyurethane resin is a two component material. 
     
     
         33 . The material of  claim 30 , wherein the resorbable polymer resin is a two-phase polymer system in which the first and second phases degrade at different rates. 
     
     
         34 . The kit of  claim 30 , further comprising one or more catalysts to control the setting time of the resin. 
     
     
         35 . The kit of  claim 30 , wherein the first filler is hydroxyapatite. 
     
     
         36 . A method of repairing a bone fracture, comprising:
 providing a first moldable, hardenable and porous material comprising a resorbable polymer resin and a filler, wherein the first material has a compressive strength that withstands compressive loads applied to a part of the bone during fracture repair;   applying the first material to an area of the bone fracture which is exposed to compressive loads during fracture repair;   providing a second moldable, hardenable and porous material comprising a resorbable polymer resin, a filler, and a pore-forming agent that provides porosity within the second material, wherein the second material has a porosity that causes bone ingrowth within a part of the bone fracture during fracture repair; and   applying the second material to an area of the bone fracture in which bony ingrowth is required during fracture repair.