Bioresorbable ceramic composition for forming a three dimensional scaffold

Abstract

The present disclosure is directed to a bioresorbable ceramic composition having a plurality of biocompatible ceramic granules, each of the granules having a coating of a plurality of calcium containing particles, where at least a portion of the particles are bound to at least a portion of an outer surface of each of the granules, and further where the composition is flowable in a dry state. The present disclosure is also directed to a three dimensional scaffold for bone repair that includes the bioresorbable composition, which upon implantation to a locus of repair defines an interconnected pore network between outer walls of the coated granules of the composition. Finally, the present disclosure is directed to methods of forming both the bioresorbable ceramic composition and the three-dimensional ceramic scaffold.

1 . A bioresorbable ceramic composition comprising:
 a plurality of biocompatible ceramic granules, each of the granules having a coating comprising a plurlaity of calcium-containing particles, at least a portion of the particles being bound to at least a portion of an outer surface of each of the granules;   wherein the bioresorbable ceramic composition is flowable in a dry state.   
     
     
         2 . The bioresorbable ceramic composition of  claim 1 , wherein the calcium containing particles are calcium sulfate, calcium phosphate, or a blend or combination of both. 
     
     
         3 . The bioresorbable ceramic composition of  claim 1 , wherein the ceramic granules are calcium phosphate granules. 
     
     
         4 . The bioresorbable ceramic composition of  claim 1 , wherein the coating is a single coating of calcium containing particles. 
     
     
         5 . The bioresorbable ceramic composition of  claim 1 , wherein the coating includes at least two coatings of calcium containing particles. 
     
     
         6 . The bioresorbable ceramic composition of  claim 1 , wherein the calcium containing particles are a mixture of α-TCP, MCPM and calcite. 
     
     
         7 . A three-dimensional bioresorbable ceramic scaffold for repairing bone defects comprising:
 a plurality of biocompatible ceramic granules, each of the granules having a coating comprising a plurlaity of calcium-containing particles, at least a portion of the particles being bound to at least a portion of an outer surface of each of the granules;   wherein the plurality of granules defines a three-dimensional scaffold at a locus of implantation; and   wherein at the time of implantation, the scaffold defines a interconnected pore network between outer walls of adjacent granules.   
     
     
         8 . The scaffold of  claim 7 , further comprising a delivery fluid. 
     
     
         9 . The scaffold of  claim 7 , further comprising a binding agent. 
     
     
         10 . The scaffold of  claim 9 , wherein the binding agent is a cementitious powder. 
     
     
         11 . The scaffold of  claim 9 , wherein the binding agent is a hydrogel 
     
     
         12 . A process for manufacturing a biocompatible ceramic composition comprising:
 mixing a plurality of calcium containing paticles and plurality of biocompatible ceramic granules;   reacting the plurality of particles and the plurality of granules with an aqueous medium;   forming a coating of the particles on at least a portion of an outer surface of each of the plurality of granules, the coating being bound to the outer surface so as to form a plurality of coated granules; and,   dehydrating the coated granules.   
     
     
         13 . The process of  claim 12 , wherein the step of dehydrating at least partially dehydrates the coated granules to remove excess unbound water. 
     
     
         14 . The process of  claim 12 , wherein the step of dehydrating includes controlling the reactivity of at least a portion of the coating such that the reactive portion is reactive to subsequent hydraulic reactions. 
     
     
         15 . The process of  claim 14 , wherein the reactive portion is calcium sulfate hemihydrate, α-TCP, or both. 
     
     
         16 . The process according to  claim 12  further comprising:
 forming at least an additional coating on the coated granules. 
 
     
     
         17 . The process according to  claim 16 , wherein the step of forming at least an additional coating is forming at least an additional two coatings on the coated granules. 
     
     
         18 . The process according to  claim 16 , wherein the step of forming the additional coating is prior to the step of dehydrating. 
     
     
         19 . The process according to  claim 16 , wherein the step of forming the additional coating is after the step of dehydrating. 
     
     
         20 . A method for forming a three-dimensional bioresorbable ceramic scaffold for bone repair comprising:
 implanting to a locus the bioresorbable ceramic composition of  claim 1 ;   contacting the composition with a binding agent; and   forming a three-dimensional scaffold having an interconnected pore network between outer walls of adjacent granules of the composition.   
     
     
         21 . The method of  claim 20 , wherein the step of implanting includes injecting the composition to the locus through a delivery device. 
     
     
         22 . The method of  claim 22 , wherein the step of implanting includes manually implanting the composition to the locus. 
     
     
         23 . The method of either of  claim 21  or  22 , wherein the composition further includes a delivery fluid.