WO2005117918A2 - Fibrous minerals, methods for their production using a solution-precursor-solid mechanism, and methods of use - Google Patents

Fibrous minerals, methods for their production using a solution-precursor-solid mechanism, and methods of use Download PDF

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WO2005117918A2
WO2005117918A2 PCT/US2005/011808 US2005011808W WO2005117918A2 WO 2005117918 A2 WO2005117918 A2 WO 2005117918A2 US 2005011808 W US2005011808 W US 2005011808W WO 2005117918 A2 WO2005117918 A2 WO 2005117918A2
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mineral
phase
fiber
inorganic
precursor
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PCT/US2005/011808
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French (fr)
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WO2005117918A3 (en
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Laurie B. Gower
Matthew J. Olszta
Yi-Yeoun Kim
Xingguo Cheng
Sara Jensen
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University Of Florida
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Priority to EP05776591A priority Critical patent/EP1793839A2/en
Publication of WO2005117918A2 publication Critical patent/WO2005117918A2/en
Publication of WO2005117918A3 publication Critical patent/WO2005117918A3/en

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    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61KPREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K33/00Medicinal preparations containing inorganic active ingredients
    • A61K33/42Phosphorus; Compounds thereof
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/14Macromolecular materials
    • A61L27/22Polypeptides or derivatives thereof, e.g. degradation products
    • A61L27/24Collagen
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/40Composite materials, i.e. containing one material dispersed in a matrix of the same or different material
    • A61L27/44Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix
    • A61L27/446Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix with other specific inorganic fillers other than those covered by A61L27/443 or A61L27/46
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/40Composite materials, i.e. containing one material dispersed in a matrix of the same or different material
    • A61L27/44Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix
    • A61L27/46Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix with phosphorus-containing inorganic fillers
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L31/00Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
    • A61L31/12Composite materials, i.e. containing one material dispersed in a matrix of the same or different material
    • A61L31/125Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix
    • A61L31/127Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix containing fillers of phosphorus-containing inorganic materials
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L31/00Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
    • A61L31/12Composite materials, i.e. containing one material dispersed in a matrix of the same or different material
    • A61L31/125Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix
    • A61L31/128Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix containing other specific inorganic fillers not covered by A61L31/126 or A61L31/127
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L31/00Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
    • A61L31/14Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L31/146Porous materials, e.g. foams or sponges
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B82NANOTECHNOLOGY
    • B82YSPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y30/00Nanotechnology for materials or surface science, e.g. nanocomposites

Definitions

  • Natural bone is a composite material consisting of both water and organic and inorganic solid phases. Bone has a hard structure because its organic extracellular collagenous matrix is impregnated with inorganic crystals, principally hydroxyapatite (Ca ⁇ 0 (PO ) 6 (OH) 2 ). Calcium and phosphate account for roughly 65% to 70% of the bone's dry weight. Collagen fibers compose approximately 95% of the extracellular matrix and account for 25% to 30% of the dry weight of bone.
  • the organic material gives bone its flexibility and resilience, while the inorganic material gives bone its strength and 2 Docket No. : UF-304XC3 rigidity (modulus), and the organization of the two phases provides a high degree of toughness to the composite.
  • UF-304XC3 rigidity module
  • the organization of the two phases provides a high degree of toughness to the composite.
  • a thorough review of bone structure from the angstrom level (mineral crystal) to the micron level (lamellae) has been presented (Weiner, S. et al. [1992] FASEB, 6:879-885).
  • Surrounding the mineralized collagen fibers is a ground substance consisting of protein-polysaccharides, or glycosaminoglycans, primarily in the form of proteoglycan macromolecules.
  • the glycosaminoglycans serve to cement together the various layers of mineralized collagen fibers.
  • the individual collagen molecules self-assemble to form triple helices, which assemble into collagen fibrils, which then assemble into microscopic fibers.
  • Within the packing of the collagen fibrils/fibers are distinct gaps, sometimes called hole zones. These hole zones are created by the staggered arrangement of tropocollagen molecules (triple helical rods), which leads to periodicity of the hole and overlap zones.
  • Various models have been proposed where these hole zones are completely isolated from each other, or are contiguous and together form a groove. Within these hole zones, mineral crystals form.
  • the mineral crystals in final form nucleate and grow within the fibrils (intrafibrillar mineralization), as well as into the interstitial spaces (interfibrillar mineralization) (Landis, WJ. et al. [1993] J. Struc Biol. 110:39-54).
  • the mineral crystals in final form are a carbonated apatite mineral (dahllite), but initially may form as an amorphous calcium phosphate phase, which then transforms into the apatite (or possibly via an octacalcium phosphate precursor, which naturally forms plates).
  • the apatite platelets of bone are of nanoscopic dimensions (only a few unit cells thick), and are densely packed into the type I collagen fibrils due to the intrafibrillar mineralization mechanism, and are well oriented with their c-axis (in the [001] direction) parallel to the long axis of the collagen fibrils. Because of the nature of the packing, the orientation of the collagen fibrils will determine the orientation of the mineral crystals (Martin, R.B. et al. [1998] "Skeletal Tissue Mechanics", Springer- Verlag Publishers, New York, N.Y.). There are numerous biocompatible artificial bone substitutes currently on the market. Of these substitutes, none successfully mimics the composite or microstructure of bone.
  • man-made ceramic composites have some of the desired properties of natural bone (such as matching of modulus), but are notoriously brittle and prone to cracking.
  • biological ceramics like bone and teeth resist cracking, 3 Docket No.: UF-304XC3 with a high toughness and stiffness.
  • UF-304XC3 3 Docket No.: UF-304XC3 with a high toughness and stiffness.
  • These mechanical properties are important because of the body's natural repair processes, in which bone is a living tissue and the cells respond according to the stresses they sense in their surrounding tissue (according to Wolffs Law).
  • the collagen fibers contain an amorphous substance during the early stages of bone formation, referred to by Bonnuci as an "inorganic substance in bands" (ISBs), which then crystallizes into the more commonly observed platy crystals (Bonnuci, E. Calcification in Biological Systems [1992] CRC Press Boca Raton, FL).
  • ISBs inorganic substance in bands
  • the nanostructure of bone is intriguing and can be difficult to define. For example, it is not clear whether bone is more 4 Docket No.: UF-304XC3 accurately characterized as a polymer-fiber-reinforced ceramic-matrix composite or a ceramic-nanoparticle-reinforced polymer-matrix composite.
  • the subject invention concerns a mineral fiber that is useful as a biomimetic substitute for bone and other tissues, such as dental enamel, and as filler in paper, paint, coatings, and plastics production.
  • the mineral fiber of the present invention comprises a fibrous mineral phase having a high aspect ratio.
  • the present invention also provides in vitro methods for making the mineral fibers, methods of using the mineral fibers to treat tissue defects, and compositions comprising the mineral fibers.
  • the method for producing the mineral fiber comprises contacting an inorganic liquid-phase mineral precursor with a crystalline inorganic substrate under conditions permitting the inorganic liquid-phase mineral precursor to solidify and crystallize, thereby forming the mineral fiber.
  • the formed mineral fiber exhibits a single crystalline birefringence and a single crystalline electron diffraction pattem.
  • the crystalline inorganic substrate can comprise any of a variety of minerals, such as calcite rhombs or hydroxyapatite. The mineral can be nucleated on a solid surface.
  • the crystalline inorganic substrate can comprise other mineral compositions 6 Docket No. : UF-304XC3 suitable for stimulating calcite nucleation from the PILP "flux" droplet.
  • the PILP "flux" droplet preferably is comprised of inorganic mineral ions that are induced to phase segregate from the mineralizing solution by attraction to an anionic polymer, under conditions permitting formation of the inorganic liquid-phase mineral precursor.
  • the anionic polymer contacted with the mineralizing solution comprises at least one member selected from the group consisting of polyacrylic acid, polymethacrylic acid, sulfonated polymer, phosphorylated proteins or peptides, phosphorylated synthetic polymers, sulfated polysaccharides, sulfated glycoproteins, polyaspartic acid, polyglutamic acid, polyaspartate, polyvinyl phosphate, and polyvinyl phosphonate, or combinations of any of the foregoing, in either their acid or salt form.
  • the inorganic liquid-phase mineral precursor comprises at least one member selected from the group consisting of calcium phosphate, calcium carbonate, hydroxyapatite, strontium carbonate, barium carbonate, and calcium sulfate, strontium sulfate, calcium oxalate, magnesium-bearing calcium carbonate, and magnesium-bearing calcium phosphate.
  • the inorganic liquid-phase mineral precursor comprises at least one member selected from the group consisting of hydroxyapatite, octacalcium phosphate, tricalcium phosphate, carbonated hydroxyapatite, fluorinated hydroxyapatite, brushite, magnesium containing hydroxyapatite, dicalcium phosphate dihydrate, and amorphous calcium phosphate.
  • Biologically active agents can be associated with the fibers of the present invention.
  • the biologically active agent can comprise at least one member selected from the group consisting of medicaments; vitamins; mineral supplements; substances used for the treatment, prevention, diagnosis, cure or mitigation of disease or illness; substances affecting the structure or function of the body; drugs; antimicrobial agents; antifungal agents; antibacterial agents; antiviral agents; antiparasitic agents; growth factors; angiogenic factors; anaesthetics; mucopolysaccharides; metals; cells; acid mucopolysaccharides; proteins; enzymes, peptides; and wound healing agents.
  • the fiber forming method further comprises forming the inorganic liquid-phase mineral precursor by combining calcium salt and an anionic polymer to form an aqueous solution, and reacting the aqueous solution with carbonate- containing vapor or solution (such as ammonium carbonate containing solution), or other counterion-containing vapors or solutions (such as phosphate, for calcium phosphate).
  • carbonate- containing vapor or solution such as ammonium carbonate containing solution
  • other counterion-containing vapors or solutions such as phosphate, for calcium phosphate
  • the aqueous solution is reacted with the ammonium carbonate-containing vapor or solution, and the ammonium carbonate-containing vapor or solution is provided through the decomposition of at least one ammonium carbonate material selected from the group consisting of ammonium carbonate monohydrate, ammonium carbonate dihydrate, and ammonium carbamate.
  • the fiber forming method can further involve forming the inorganic liquid-phase mineral precursor by combining calcium chloride and a combination of anionic polymers to form an aqueous solution, and reacting the aqueous solution with ammonium phosphate vapor or with a phosphate-containing solution, preferably in the presence of Tris-buffered saline (Tris hydroxymethyl aminomethane hydrochloride; Trizma base; sodium chloride), at a pH of about 7.4.
  • Tris-buffered saline Tris hydroxymethyl aminomethane hydrochloride; Trizma base; sodium chloride
  • buffers such as HEPES (N-2-hydroxyethylpiperazine-N'-2'ethanesulfonic acid); BIS-TRIS (bis- 2-hydroxyethyl-amino]tris-(hydroxymethyl)methane); CHES (2-
  • the method involves forming the inorganic liquid-phase mineral precursor by combining calcium salt and a combination of anionic polymers to form an aqueous solution, and reacting said aqueous solution with phosphate generated by enzymatic degradation of phosphate containing compounds.
  • the method involves forming the inorganic liquid-phase mineral precursor by combining calcium salt and ammonium phosphate, and a combination of anionic polymers to form an aqueous solution, in which precipitation is caused by at least one of the following conditions: a change of temperature, a change of pH, evaporation, or removal of crystallization inhibitor.
  • the inorganic liquid-phase mineral precursor can be contacted with the crystalline inorganic substrate under various conditions.
  • the inorganic liquid-phase mineral precursor is contacted with the crystalline inorganic substrate in an aqueous solution at a temperature of 4° C or higher.
  • the contacting of the inorganic liquid-phase mineral precursor with the crystalline inorganic substrate involves contacting droplets of the inorganic liquid-phase mineral precursor with the crystalline inorganic substrate, wherein the droplets coalesce and solidify, and wherein the inorganic fiber is formed outward from the interface of the droplets and the crystalline 8 Docket No.: UF-304XC3 inorganic substrate.
  • the droplets of inorganic liquid-phase mineral precursor include primary droplets that contact the crystalline inorganic substrate and secondary droplets that contact the primary droplets, wherein the secondary droplets extend the length of the inorganic fiber.
  • the secondary droplets extend the length of the inorganic fiber in a continuous fashion as a PILP phase is continuously generated through constant composition or batch replenishment techniques.
  • the inorganic liquid-phase mineral precursor can crystallize in an epitaxial orientation to the seed substrate, or may solidify first, crystallizing independently of the seed substrate.
  • the inorganic crystalline substrate is a film.
  • the inorganic liquid-phase mineral precursor comprises ions which precipitate into hydroxyapatite or other calcium phosphate phases, and the inorganic crystalline substrate comprises a hydroxyapatite film.
  • the mineral fibers formed using the methods of the present invention have a high aspect ratio (length to diameter) in the range of about 5 (5:1) to 60 (60:1). In some embodiments, the fiber aspect ratio will be in the range of about 10 (10:1) to 60 (60:1).
  • the formed fiber also has a mineral phase that is homogenously distributed throughout the width (cross-section) of the fiber (i.e., not a hollow cylinder).
  • the mineral fibers formed have a diameter within the range of about 100 nm to 2 ⁇ m. Small individual fibers can be grown together in the same direction, thereby forming a fiber bundle of larger diameter (e.g., 100 nm to 1mm).
  • the mineral fiber of the present invention does not comprise a metal.
  • Figures 1A-1D show a schematic representation of mineral fiber formation according to a method of the present invention.
  • the polymer-induced liquid-precursor (PILP) phase is separated from solution in the form of nm- ⁇ m diameter droplets 10 of PILP phase.
  • these droplets then physisorb onto an existing crystalline (e.g., calcite) surface 20 and either solidify (• denoted by closed circle) or remain liquid (o denoted as an open circle).
  • IC subsequent droplets 10 that contact a solid primary droplet wick to the surface and form a film 30 surrounding the solid droplet. Secondary droplets that contact the primary liquid droplet coalesce with it.
  • FIG. 1 shows micrographs demonstrating, respectively, classical calcite nucleation, thin films deposited via a polymer-induced liquid-precursor (PILP), and calcite overgrowth on calcite via traditional solution growth (in the absence of the PILP phase).
  • PILP polymer-induced liquid-precursor
  • Figures 3A-3C show micrographs of calcium carbonate fibers of the present invention extending from a crystalline substrate (calcite rhombs).
  • Figures 4A-4K show a schematic representation of mineral fiber formation with integrated micrographs of calcite rhombs 60 nucleated on a surface 70 (forming a crystalline inorganic substrate), PILP droplets 10 adsorbing to a rhomb substrate 60 ( Figures 4A-4E), and fibers 40 forming therefrom ( Figures 4F-4K).
  • Figures 5A-5C show micrographs of serpentine fibers produced by the mechanism of the present invention (which resemble serpentine fibers of semiconductor materials produced by the VLS and SLS mechanisms) ( Figure 5A) and bobble tips on the fibers of the present invention ( Figures 5B and 5C) resembling the "flux" droplets observed in VLS/SLS mechanisms.
  • Figures 6A-6B shows that fibers can be formed in mineral systems other than calcium carbonate.
  • Figure 6A shows a scanning electron micrograph of a dense mat of barium carbonate fibers which were stimulated to grow on the surface of a calcite rhomb.
  • Figure 6B shows a transmission electron micrograph of one isolated fiber which is approximately 8 nm in diameter, and its corresponding electron diffraction pattem, demonstrating that the fiber, and is single crystalline, with spacings that match the witherite phase of BaCO 3 .
  • Figures 7A-7D show a schematic representation of the microcontact printing technique used for micropatterning thin films of calcium carbonate or calcium phosphate. Self-Assembled Monolayers (SAMs) with controlled surface functionality are patterned using a PDMS "stamp" dabbed with an alkane thiol "ink”.
  • Figure 7A is an optical micrograph of the PDMS stamp with a micro-channel pattern.
  • Figure 7B shows patterning of a SAM containing COOH and/or OH functional groups by micro-contact 10 Docket No.: UF-304XC3 printing the SAM on the Au surface.
  • Figure 7C shows patterned surface is placed upside- down in a crystallization solution to avoid post-precipitates.
  • Figure 7D shows that crystals preferentially nucleate on the SAMs with carboxylate functionality, and droplets of the amorphous precursor phase are deposited exclusively on the preferential SAM surface.
  • Figures 8A-8F show calcitic films patterned via deposition of PILP phase on microcontact printed SAMs, which contained carboxylate-terminated alkane thiol on grid regions and methyl-terminated alkane thiol (or gold) on the remaining area (interior squares).
  • Figure 8 A is an optical micrograph (with l st -order red waveplate) of calcite crystals shaped into a "grid-like" pattern. The reaction conditions were 12 mM to 24mM Ca-ion, 12 ⁇ g/ml PAA, at a temperature of at 4°C.
  • Figure 8B shows a scanning electron micrograph of CaCO 3 fibrous outgrowths formed at relatively high concentrations of anionic polymer (60 ⁇ g/ml polyacrylic acid), which leads to a secondary induction of PILP phase which collects at the edge of the pre-pattemed mineral film, and is stimulated to extend into fibrous outgrowths.
  • Figure 8C shows a higher magnification view of some of the fibers of Figure 8B.
  • Figure 8D shows dense fibrous arrays formed at the edges of some of the patterned mineral films, in which the fibers adhere into coherent outgrowths resembling "horsetails".
  • Figure 8E shows dense fibrous mats formed under similar conditions, except for a higher calcium concentration of 24 mM Ca-ion.
  • Figure 8F is a higher magnification view of Figure 8E, showing highly packed but relatively short mineral fibers.
  • Figures 9A-9D show that hydroxyapatite can also be patterned into thin films, but with a high degree of surface texture that may be suitable to stimulate fiber formation.
  • Figures 9A-9C show elemental mapping from Energy Dispersive Spectroscopy, demonstrating the composition of the hydroxyapatite mineral (Ca and Phosphorous absorption), which conforms to the micro-patterned self-assembled monolayer of COOH- (CH 2 )nSH.
  • Figure 9D shows a higher magnification SEM image of a single stripe of patterned HA, showing that the film is polycrystalline, composed of nanoscopic platelets of hydroxyapatite.
  • Figures 10A-10B show a comparison of calcite rhomb seed crystals grown by the solution method ( Figure 10A) and gel method ( Figure 10B), the latter of which leads to higher surface defect texture.
  • the present invention pertains to mineral fibers and in vitro methods for producing mineral fibers utilizing an inorganic liquid-phase mineral precursor (PILP).
  • PILP inorganic liquid-phase mineral precursor
  • the fiber forming method of the present invention the PILP is contacted with a crystalline inorganic substrate under conditions permitting the PILP to solidify, crystallize, and extend away from the crystalline substrate, thereby forming the mineral fiber.
  • the mineral fibers typically grow or extend in a substantially unidirectional manner, away from the crystalline substrate (thereby forming substantially linear mineral fibers).
  • the fibers When there are fluctuations in the reaction, such as the temperature of the crystallizing solution, the fibers appear to grow in a serpentine manner, much like the serpentine growth exhibited by the fibers produced by the vapor-liquid-solid (VLS) mechanism or solution-liquid-solid (SLS) mechanism when the temperature is varied, as described by Trentler T.J. et al. (Trentler, T.J. et al. [1995] Science, 270(5243):1791-1794; Wagner, R.S. and W.C. Ellis, [1964] Applied Physics Letters, 4(5):89; Wagner, R.S. and W.C. Ellis, [1964] Journal of Metals, 16(9): 761).
  • VLS vapor-liquid-solid
  • SLS solution-liquid-solid
  • the inorganic liquid-phase mineral precursor utilized to form mineral fibers of the present invention can be produced using a variety of methods. For example, synthesis of a liquid-phase precursor of calcium carbonate has been described previously (Gower, L.B. and D.J. Odom [2000] J. Crystal Growth 210(4):719-734; Gower, L.A. [1997] "The Influence of Polyaspartate Additive on the Growth and Morphology of Calcium 12 Docket No.: UF-304XC3
  • Alternative methods can be used to gradually raise the supersaturation of the crystallizing solution, including direct addition of a carbonate containing solution to the calcium containing solution; or the escape of carbon dioxide gas from a saturated calcium bicarbonate solution (which is produced by bubbling carbon dioxide into an aqueous solution containing the calcium carbonate salt).
  • Supersaturation can also be raised using temperature, pH, or removal of inhibitory species. Similar methods can be used for the calcium phosphate system, although higher temperature (37° C) is more favorable for decomposition of ammonium phosphate (or any derivations of ammonium phosphate, such as ammonium phosphate dibasic).
  • the phosphate counterion can be produced using enzymes that cleave phosphate-containing moieties, or through the degradation of phosphate containing phospholipid vesicles such as seen in Murphy and Messersmith (W. L. Murphy, P. B. Messersmith, Compartmental control of mineral formation: adaptation of a biomineralization strategy for biomedical use. Polyhedron, 2000, 19:357).
  • Mineral- containing solutions such as carbonate-containing or phosphate-containing solutions can have an effective concentration of mineral for fiber formation (such as 0.5 mM to 10 mM).
  • the crystalline substrate can then be contacted with the liquid-phase precursor of the inorganic mineral, such as calcium phosphate, calcium carbonate, hydroxyapatite, barium carbonate, strontium carbonate, calcium sulfate, calcium oxalate, calcium oxide, magnesium-bearing calcium carbonate or phosphate, or any polymorphs of these minerals.
  • the crystalline inorganic substrate used in the fiber forming method permits epitaxial interaction within the crystallization mechanism.
  • the crystalline substrate can comprise any of a variety of minerals, such as calcite rhombs or hydroxyapatite. It is not necessary that the crystalline substrate be a solid crystal.
  • the crystalline substrate can be a mineral film or thin film.
  • films comprising one or more 13 Docket No. : UF-304XC3 of CaCO , CaPO 4 , BaCO 3 , and SrCO 3 can be used.
  • the film is a patterned film, which allows control of fiber location, morphology, and/or orientation.
  • Fibers can be removed from the crystalline inorganic substrate by any suitable method.
  • the fibers can be removed from the substrate by centrifugation.
  • anionic polymers such as anionic short-chained polymers, can be utilized to initiate the amorphous liquid-phase mineral precursor, including different polymers and biological materials.
  • Polyacrylic acid PAA
  • polymethacrylates PMA
  • sulfonated polymers PAA
  • phosphorylated proteins peptides and polymers
  • sulfated glycoproteins polyaspartic acid, polyglutamic acid, polyaspartate, polyvinyl phosphate, and blends or copolymers of these materials, individually and in mixtures, can be utilized to induce the liquid-phase separation, for example.
  • a range of polymer molecular weights can be suitable if the other variables of the crystallizing conditions are appropriately modified to generate the PILP phase.
  • molecular weights in the range of 2,000 to 15,000g/mol enhance the ability to induce formation of the precursor.
  • the methods of the subject invention can be carried out under a variety of conditions.
  • the fiber forming method can be carried out at a temperature of about 0° C to about 100° C.
  • the method is carried out at about 4° C or higher. More preferably, the method is carried out at about 37° C, to match physiological conditions.
  • the method can be carried out at a pH in the range of about 5 to about 10.
  • the method is carried out at a pH of about 7.0 to about 7.8 and 1 atm. More preferably, the method is carried out at a pH of about 7.4.
  • the type of reaction vessel or vessels utilized for producing the mineral fibers of the present invention, or their sizes, are not critical.
  • any vessel or substrate capable of holding or supporting the PILP and/or crystalline substrate so as to allow the reaction to take place can be used.
  • the supersaturation is gradually increased, allowing time for the anionic polymer to induce and stabilize the liquid-phase mineral precursor.
  • the terms "adding”, “contacting”, “mixing”, “reacting”, “combining” and grammatical variations thereof, are used interchangeable to refer to the mixture of reactants of the process of the present invention (e.g., anionic polymer additives, calcium-containing solution, and so forth), and the reciprocal mixture of those reactants, one with the other (i.e., vice-versa).
  • the mineral fibers formed using the methods of the present invention typically have a high aspect ratio (length to diameter) in the range of about 5 (5:1) to 60 (60:1). In some embodiments, the fiber aspect ratio will be in the range of about 10 (10:1) to 60 (60:1).
  • the formed fiber has a mineral phase that is homogenously distributed throughout the width (cross-section) of the fiber (i.e., not a hollow cylinder).
  • the mineral fibers formed have a diameter within the range of about 100 nm to 2 ⁇ m. Small individual fibers can be grown together in the same direction, thereby forming a fiber bundle having a larger diameter (e.g., 100 nm to 1 mm).
  • the mineral fiber of the present invention need not include a metal.
  • the present invention further concerns a method of treating a patient having a tissue defect by applying mineral fibers of the subject invention (and compositions comprising the fibers) to the site of the tissue defect.
  • the term "patient” refers to any human or non-human animal suffering from a tissue defect.
  • a therapeutically effective amount of the fibers or composition can be applied at the site of a tissue defect to partially or fully restore structural integrity to the tissue.
  • the mineral fibers of the subject invention can function as a filler (or partial filler) or plug, to mend the tissue defect. The amount to be applied will depend upon the size and nature of the tissue defect, and the clinical outcome that is sought.
  • the fibers can be applied within a composition in a malleable form, for example, as a paste or putty, such that the administered composition takes the shape of the bone defect.
  • the composition can be molded pre-cast into a desired shape (such as the shape of the defect) using polymer composition molding methods known to those of ordinary skill in the art, and the molded composition can be administered as a solid or semi-solid article.
  • the size, volume, thickness, and shape of the molded article can be controlled, as desired.
  • the composition can be applied in particulate form.
  • the mineral fibers can be applied so that they directly contact existing tissue adjacent to, or defining, the tissue defect site, or the mineral fibers can be contacting another implant, or both.
  • composition of the subject invention can be applied to the tissue defect site as a liquid. Once applied, with a syringe for example, the liquid composition can coagulate or cure ("set") shortly after application to form a solid. 15 Docket No.: UF-304XC3
  • the mineral fibers of the subject invention and compositions comprising the fibers) can be used as a vehicle for the in situ delivery of biologically active agents.
  • the biologically active agents incorporated into, or included as an additive within, the fibers of the subject invention can include, without limitation, medicaments, growth factors, vitamins, mineral supplements, substances used for the treatment, prevention, diagnosis, cure or mitigation of disease or illness, substances which affect the stmcture or function of the body, or drugs.
  • the biologically active agents can be used, for example, to facilitate implantation of the mineral fibers into a patient and to promote subsequent integration and healing processes.
  • the active agents include, but are not limited to, antifungal agents, antibacterial agents, anti-viral agents, anti -parasitic agents, growth factors, angiogenic factors, anaesthetics, mucopolysaccharides, metals, cells, and other wound healing agents.
  • biologically active agent such as live cells can be incorporated into fiber constructs during their formation, or subsequently allowed to infiltrate the fibers or compositions through tissue engineering techniques.
  • cells can be seeded onto and/or within the mineral fiber constructs of the present invention.
  • tissues such as cartilage can be associated with the mineral fibers prior to implantation within a patient. Examples of such cells include, but are not limited to, bone cells (such as osteoclasts, osteoblasts, and osteocytes), blood cells, epithelial cells, neural cells (e.g., neurons, astrocytes, and oligodendrocytes), and dental cells (odontoblasts and ameloblasts).
  • Seeded cells can be autogenic, allogenic, or xenogenic. Seeded cells can be encapsulated or non- encapsulated.
  • antimicrobial agents that can be used in the present invention include, but are not limited to, isoniazid, ethambutol, pyrazinamide, streptomycin, clofazimine, rifabutin, fluoroquinolones, ofloxacin, sparfloxacin, rifampin, azithromycin, clarithromycin, dapsone, tetracycline, erythromycin, cikprofloxacin, doxycycline, ampicillin, amphotericine B, ketoconazole, fluconazole, pyrimethamine, sulfadiazine, clindamycin, lincomycin, pentamidine, atovaquone, paromomycin, diclarazaril, acyclovir, trifluorouridine, foscamet, penicillin, genta
  • Bone growth factors that can be incorporated into the fibers and compositions of the present invention include, but are not limited to, bone growth factors (e.g., BMP, OP-1) basic fibroblast growth factor (bFGF), acidic fibroblast growth factor (aFGF), nerve growth factor (NGF), epidermal growth factor (EGF), insulin-like growth factors 1 and 2 (IGF-1 and IGF-2), platelet-derived growth factor (PDGF), tumor angiogenesis factor (TAF), vascular endothelial growth factor (VEGF), corticotropin releasing factor (CRF), transforming growth factors alpha and beta (TGF- ⁇ and TGF-/3), interleukin-8 (IL-8), granulocyte-macrophage colony stimulating factor (GM-CSF), the interleukins, and the interferons.
  • bone growth factors e.g., BMP, OP-1 basic fibroblast growth factor (bFGF), acidic fibroblast growth factor (aFGF), nerve growth factor (NGF), epiderma
  • agents that can be incorporated into the fibers or compositions of the subject invention include acid mucopolysaccharides including, but not limited to, heparin, heparin sulfate, heparinoids, dermatan sulfate, pentosan polysulfate, chondroitin sulfate, hyaluronic acid, cellulose, agarose, chitin, dextran, carrageenin, linoleic acid, and allantoin.
  • Proteins that can be incorporated into, or included as an additive within, the fibers or compositions of the subject invention include, but are not limited to, collagen (including cross-linked collagen), fibronectin, laminin, elastin (including cross-linked elastin), osteopontin, osteonectin, bone sialoproteins (Bsp), alpha-2HS-glycoproteins, bone Gla-protein (Bgp), matrix Gla-protein, bone phosphoglycoprotein, bone phosphoprotein, bone proteoglycan, protolipids, bone morphogenetic protein, cartilage induction factor, platelet derived growth factor and skeletal growth factor, enzymes, or combinations and biologically active fragments thereof.
  • proteins associated with other parts of human or other mammalian anatomy can be incorporated or included as an additive, including proteins associated with cartilage, such as chondrocalcining protein, proteins associated with dentin, such as phosphoryin, glycoproteins and other Gla proteins, or proteins associated with enamel, such as amelogenin and enamelin.
  • Agents incorporated into the fibers or compositions of the subject invention may or may not facilitate or enhance osteoinduction.
  • Adjuvants that diminish an immune response can also be used in conjunction with the fibers or compositions of the subject invention.
  • the biologically active agents can first be encapsulated into microcapsules, microspheres, microparticles, microfibers, reinforcing fibers and the like to facilitate mixing and achieving controlled, extended, delayed and/or sustained release. 17 Docket No. : UF-304XC3
  • Encapsulating the biologically active agent can also protect the agent against degradation during formation of the fibers or compositions of the invention.
  • the biologically active agents can be pendantly attached to the PILP phase or the formed fibers. The attachment can be facilitated through covalently linking the agent to inorganic phase, or through the use of hydrogen bonding.
  • the biologically active agent is controllably released into a mammal when the fibers or composition of the invention is implanted into a mammal, either through degradation in the aqueous environment, or more preferably, due to bioresorption relying on the time scale resulting from cellular remodeling.
  • the fibers or fibrous constructs of the subject invention can be used to replace an area of discontinuity in the tissue in the mammalian body.
  • the area of discontinuity in the tissue can be as a result of trauma, disease, genetic defect, tumor, or surgery, for example.
  • the compositions of the subject invention can be formulated into a variety of shapes suitable for its function as a tissue implant, such as a plate, pin, rod, screw, anchor, tack, arrow, staple, button, or other regular or irregular shape.
  • the composition of the present invention can be formulated as a three-dimensional scaffold and, optionally, seeded with one or more cell types for implantation within a patient.
  • a hydroxyapatite (HAP) containing PILP can be used to produce fibrous HAP for dental applications. Teeth are composed of various biomineral layers, with the enamel layer being composed of fibrous HAP.
  • tissue defect refers to any tissue deficient region, such as a void, gap, recess, or other discontinuity in the hard or soft tissues.
  • the tissue defect can be artificially or naturally established, and can occur due to disease or trauma, for example.
  • the tissue defect can occur as a consequence of pathologic, inflammatory, or tumor diseases, surgical interventions, congenital defects, or bone fractures, and the like.
  • tissue defects in dental applications will be on or within the gum or jaw of the patient's mouth.
  • the tissue defect is artificially established by removing the tumor tissue.
  • the mineral fibers or compositions containing the 18 Docket No.: UF-304XC3 mineral fibers can be applied, for example, to repair periodontal defects, for craniofacial reconstruction, joint reconstruction, fracture repair, to conduct orthopedic surgical procedures, and spinal fusion, for example.
  • the term "tissue defect” is also intended to include anatomical sites where augmentation to a tissue feature is desired by the patient in the absence of disease or trauma, such as in elective cosmetic surgery.
  • the "defect" can be one that is subjectively perceived by the patient, and where augmentation of the bone deficient region is desired.
  • polymorph refers to inorganic minerals that are similar in chemical composition but have different crystal structures.
  • the terms “comprising”, “consisting of, and “consisting essentially of are defined according to their standard meaning and may be substituted for one another throughout the instant application in order to attach the specific meaning associated with each term.
  • the singular forms "a”, “an”, and “the” include plural reference unless the context clearly dictates otherwise.
  • a reference to “a fiber” includes more than one such fiber, and the like.
  • an anionic polymer includes more than one such polymer, and the like.
  • the mineral fibers of the present invention may be used as filler in plastics, paint, coatings, and paper production.
  • calcium carbonate is used in a wide range of plastics as a filler, most notably PVC piping.
  • Calcium carbonate fibers of the present invention are particularly useful in these applications because they have high aspect ratios that enhance reinforcement (modulus and strength), and their small size provide excellent surface area for adhesion to the matrix phase.
  • calcite has a Moh's hardness of 3.
  • aragonite which naturally forms needlelike crystals and is currently the only "fibrous" calcium carbonate available for filler, has a Moh's hardness of 4, making it slightly harder than calcite.
  • the needle-like shape of aragonite crystals are not in the form of individual fibers, but are packed within spherulitic bundles which are not readily separated as isolated fibers for manipulation into the above composites. 19 Docket No. : UF-304XC3
  • PILP Polymer-Induced Liquid-Precursor
  • the general process introduces the anionic polymer into an aqueous salt solution which is slowly raised in supersaturation.
  • One common method for raising supersaturation is to slowly introduce one of the ionic species, for example using a modified vapor diffusion technique developed by Addadi et al. (Addadi, L. et al. [1985]
  • the crystal products are deposited onto a thin glass coverslip (22 mm
  • micron sized calcite rhombs (20-40 ⁇ m) were deposited on glass slides via a vapor diffusion method (Addadi, L., Moradian, J., Shay, E., Maroudas, N. G. and Weiner, S., Proc. Natl. Acad. Sci. U.S.A., 1987, 84:2732-2736).
  • a vapor diffusion method (Addadi, L., Moradian, J., Shay, E., Maroudas, N. G. and Weiner, S., Proc. Natl. Acad. Sci. U.S.A., 1987, 84:2732-2736).
  • larger, millimeter sized calcite rhombs were grown through a metasilicate gel method.
  • glass substrates 22 mm diameter microscope coverslips
  • this crystallizing solution was placed in an enclosed chamber (e.g., a desiccator) containing small vials of freshly crushed ammonium carbonate.
  • the carbonate powder decomposes into a vapor (CO 2 and NH 3 ) at room temperature, which slowly diffuses into the calcium solution, providing a means for gradually raising the supersaturation of CaCO 3 .
  • the larger 0.5 mm calcite crystals were fabricated in a gel medium through a controlled chemical reaction method.
  • a sodium metasilicate gel was prepared using 0.5 M CaCl 2 *H 2 O (SIGMA) in a 0.35 M Na 2 O 3 Si «9H 2 O (SIGMA) solution, which was allowed to set in 15 mm dia/127 mm long glass test tubes overnight until gelation. Subsequently, 0.1 M ammonium carbonate solution was added to each test tube and then covered with parafilm. The ammonium carbonate was allowed to diffuse into the gel over a period of 1 month, at which time large calcite crystals were gently removed with tweezers and rinsed several times with deionized water. The larger calcite crystals were analyzed using EDS in order to assure no Si remained on the surface of the crystals.
  • Figure 10A shows a representative gel grown seed
  • Figure 10B shows a higher fiber density on the surface of this type of seed crystal.
  • the present evidence suggests that the surface texture of the seed crystal is important for stimulating fiber formation. This may arise due to accumulation of a sufficient amount of PILP droplets to form a "flux" droplet. It appears that small PILP droplets rapidly solidify when adsorbed to a solid substrate, but the present inventors have observed that thicker accumulations of PILP droplets remain fluidic.
  • the fluidity of the precursor is presumed to be critical to fiber formation; therefore, this ability to generate a fluidic "flux" droplet may be enhanced with the appropriate surface texture that accumulates some quantity of fluidic precursor phase.
  • a desirable size for a "flux" droplet appears to be in the range of approximately 100 nanometers to approximately five microns in size.
  • the flux droplet is in the range of approximately 100 nanometers and 3 microns in size.
  • modulating the surface texture of the seed substrate can be used to regulate fiber morphology, such as size (length and diameter) and quality (surface roughness and internal crystallinity), as well as location (for patterning fiber bundles or arrays). Arrays of fibers can be formed in a random or organized format (rows, columns, etc.).
  • calcite surfaces tailored to have specific surface density characteristics can be made following Teng (H. H. Teng, Controls by saturation state on etch pit formation during calcite dissolution. Geochimica Et Cosmochimica Ada 68, 253 (Jan, 2004)). Briefly, Teng found that by cleaving a large optical-quality Iceland spar (calcite) with a razor blade, to expose the ⁇ 10-14 ⁇ face, he could study the surface dissolution kinetics via the addition of solutions undersaturated with respect to CaCO . He concluded that when the saturation index ⁇ > 0.541 ( ⁇ is defined as the ratio of ionic activity product to solubility product), no etch pit formation was observed, and dissolution occurred at existing steps.
  • etch pits In addition to etch pits, other options for accumulating the PILP phase can include pattern scratches or indents on the surface (such as from a nano or micro indenter), or pattern substrate films with edges that collect PILP droplets, or impurity incorporation into the seed crystal, which leads to higher surface defects (as shown by the gel grown calcite rhomb in Figure 10B). Impurities can be incorporated into the crystals during their formation, such as other inorganic ions or molecular compounds, including polymeric additives. Controlling fiber morphology, fiber orientation, and fiber density on the substrate is particularly useful for making patterned arrays or for building a composite structure. For example, control of fiber orientation will be particularly useful for fabrication of nanowires, circuits, etc.
  • the third method for accumulating PILP phase in accordance with the present invention is to make crystalline films (such as crystalline calcium carbonate thin films), which can accumulate PILP phase at the edges, for fiber deposition substrates, utilizes the method described by Gower (Gower, L.B. and D.J. Odom J. Crystal Growth, 2000, 210(4):719-734) as a component.
  • Gower Gower, L.B. and D.J. Odom J. Crystal Growth, 2000, 210(4):719-734
  • glass substrates 22 mm diameter microscope coverslips
  • SIGMA 24 mM CaCl 2 «H 2 O
  • This crystallizing solution was placed in an enclosed chamber (e.g., a desiccator) containing small vials of freshly crushed ammonium carbonate.
  • the resultant film is crystalline calcium carbonate.
  • the mineral films can also be patterned in order to template the location of fiber formation by using the soft lithography technique of microcontact printing (Aizenberg, j. et al. Nature, 1999, 398:495-498).
  • Self-assembled monolayers (SAMs) of controlled surface functionality can be "stamped" onto substrates to regulate the location where the mineral precursor will deposit (or where solution crystals nucleate, as shown by Aizenberg [Aizenberg, J. et al. Nature, 1999, 398:495-498]).
  • alkane thiol groups can be patterned onto gold-coated substrates, and chosen to have endgroups containing charged, polar, or non-polar head groups, which preferentially stimulate mineral formation on the monolayers with charged or more polar headgroups (Kim, Y.-Y. and L.B. Gower "Formation of complex non-equilibrium morphologies of 23 Docket No. : UF-304XC3 calcite via biomimetic processing" Materials Research Society, San Francisco, MRS, 2003).
  • silanol chemistry can be used to pattern surfaces (such as glass) with silane coupling agents of controlled surface functionality. Formation of Fibrous Crystals.
  • the substrate crystals were introduced into the crystallizing system by placing the glass coverslips which had nucleated the 20 - 40 ⁇ m calcite rhombs (or contained 3 to 4 of the larger gel grown rhombs or films) in the bottom of a small petri dish filled with 3 ml of a 12 mM calcium chloride dihydrate solution, containing 0.24 mM MgCl 2 *6H 2 O or SrCl 2 »6H O, along with 200 ⁇ g/mL of polyacrylic acid (5,100 M.W., SIGMA) to induce the PILP process (Gower, L.B. and Odom, D.J. J. Crystal Growth, 2000, 210:719-734).
  • coverslips containing the small rhomb substrate crystals were carefully removed from solution with tweezers and rinsed with ultrapure H 2 O and then with ethanol (by gently dipping coverslip in a rinse beaker to avoid dislodging the fragile fibers) in order to remove any soluble salts.
  • the glass slides were then examined using an Olympus BX- 60 optical microscope in transmission mode, using crossed polars and an optional first- order-red wave plate.
  • Polarized Optical Light Microscopy (POM) Analysis Samples were examined on the glass slides in transmission mode using an Olympus BX60 polarized optical microscope with first-order red wave-plate.
  • the wave-plate allows one to observe both amorphous and crystalline phases, which is quite useful for examining crystallization reactions that proceed via precursor mechanisms. In this case, it was also useful for examining the crystallographic orientation of the fibers.
  • PPL polarizer
  • Calcite is an optically negative material, therefore when the slow vibration direction of the wave-plate (indicated as "sd" double arrow) is parallel with the slow axis of the calcite (indicated by short arrow in NE comer), the combined vibrations will destmctively interfere and the fiber will appear blue (a fall in interference color determined from Michel Levy chart). Conversely, the yellow color in the opposite quadrants indicates the slow ray of the crystal is parallel to the slow direction of the accessory plate.
  • This type of analysis allows one to identify if there is a uniform orientation of the crystallographic axes within irregular shaped crystals, such as the fibers described here. Scanning Electron Microscopy (SEM) Analysis.
  • the samples were dried overnight, fixed to an aluminum stub using carbon paste or double-sided copper tape and then Au/Pd coated. The samples were then examined with either a JEOL 6400 SEM or a JEOL 6335F FEGSEM instrument, both equipped with energy dispersive spectrometers (EDS), at an accelerating voltage of 15kV. Transmission Electron Microscopy (TEM) Analysis. In order to examine the fibrous calcium carbonate, the samples were first scratched with a razor blade to dislodge some of the fibers from the rhomb substrate. A small aliquot of ethanol was then dispensed onto the scratched area and immediately drawn up using a micropipette.
  • TEM Transmission Electron Microscopy
  • the removed aliquot was then dropped onto a 200 mesh copper TEM grid coated with thin layers of Formvar and amorphous carbon.
  • the grid was air-dried and subsequently sputter coated with amorphous carbon for stability.
  • the sample was examined on a JEOL 200cx or 201 OF transmission electron microscope at 200 kV in brightfield (BF) and selected area diffraction (SAD) modes.
  • Example 1 Calcium Carbonate Fibers Fibrous calcium carbonate (CaCO 3 /calcite) crystals 100-800 nm in diameter were produced at temperatures as low as 4° C.
  • the calcium carbonate fibers were deposited 25 Docket No.: UF-304XC3 onto calcite rhombs using a mineralization process involving the inclusion of short- chained anionic polymers (e.g., polyaspartic acid or polyacrylic acid) to a supersaturated calcium carbonate system to induce an amorphous liquid-phase precursor.
  • PILP polymer-induced liquid-precursor
  • fibrous crystals which exhibited a single crystalline birefringence, were observed growing from each of the faces.
  • the fibrous crystals were identified as calcite using electron diffraction, and although the diffraction patterns were single crystalline in nature, brightfield (BF) transmission electron microscopy (TEM) images of the majority of fibers showed distinct grains, suggesting that they are polycrystalline with all of the grains aligned in the same orientation. Scanning electron microscopy (SEM) shows the surface of the fibers sometimes appear to be covered in iso-oriented calcite rhombs.
  • the fibers continue to grow, restricted to one dimensional growth by the dimension of the flux droplet containing the reactants.
  • the amorphous liquid-precursor (PILP) droplets begin to deposit on the mineral face and either solidify or remain partially liquid-like. If the primary droplets solidify, subsequent droplets wick to the side of these droplets and form a film.
  • Example 2 Hydroxyapatite (HA) Fibers Enamel, the hardest known vertebrate tissue, is comprised of "rods" of hydroxyapatite tightly packed together in an organized array. Enamel and dentin share a unique starting point, the dentino-enamel junction (DEJ), with the enamel growing away from the DEJ to serve as the mastication surface, and the dentin growing in towards the pulp. While researchers agree that dentine is the first to appear, there is still debate as to whether the enamel epitaxially nucleates from the dentine surface (G. W. Bernard, Ultrastructural observations of initial calcification in dentin and enamel. Journal of Ultras compture Research 41, 1 (1972).; E. J.
  • ion reactants such as solutions containing calcium chloride and potassium phosphate.
  • a supersaturated solution of calcium phosphate is formed by addition of equal volumes of 9 mM CaCl 2 and 4.2 mM of 28 Docket No.: UF-304XC3
  • the CaPO PILP process involves adding Poly(Aspartic acid- sodium salt), at concentrations to induce the liquid-phase amorphous mineral precursor (in the range of 5 to 100 ⁇ g/ml).
  • the glass slides with the hydroxyapatite crystals are placed in the mineralizing solution containing the anionic polymer, allowing the CaPO 4 PILP phase to deposit onto the CaP seed crystals.
  • Example 3 Barium Carbonate Fibers Fibrous barium carbonate (BaCO /witherite) crystals 50-100 nm in diameter and several microns in length were produced on calcium carbonate seeds at temperatures as low as 4° C ( Figure 6A).
  • the barium carbonate fibers were deposited onto calcite rhombs or films using the polymer-induced liquid-precursor (PILP) process, outlined in Example 1.
  • PILP polymer-induced liquid-precursor
  • Example 1 When no polymer was used to induce the PILP process, witherite aggregates heterogeneously nucleated on the calcite seed surface. When polymer was added, fibrous crystals were observed growing from some of the faces. The fibrous crystals were identified as witherite using electron diffraction ( Figure 6B). Brightfield (BF) transmission electron microscopy (TEM) images of the majority of fibers shows they were bent, possibly as a result of twinning. The bent, or fluidic, nature of the fibers was confirmed using SEM. It is also possible that these bends arise from fluidic flow of the liquid precursor phase during fiber formation. Given the similarity in reaction conditions, it is presumed that the barium carbonate fibers nucleate and grow by the SLS process described in Example 1.
  • BF transmission electron microscopy
  • Figures 6A and 6B show barium carbonate fibers of the present invention.
  • This work with BaCO shows that different minerals can be stimulated to form by this SPS mechanism, suggesting that it could be a more generalized mechanism applicable to a variety of inorganic phases.
  • this work shows that a crystallographic phase can be produced that differs from the phase comprising the seed substrate, suggesting that an epitaxial match is not needed to induce fiber formation.
  • 29 Docket No.: UF-304XC3 A different type of "seed" substrate was found to stimulate fiber formation. In this case, the substrate was composed of thin films of calcium carbonate, which appeared to stimulate fibers to grow at the edges of the films, which are high in surface energy, similar to a crystal defect.
  • Figures 7A-7D show a schematic of the microcontact printing technique used to pattern the calcite film shown in Figure 8A. Because the initial filmlike mineral can be patterned using the soft lithography technique of microcontact printing, the location of the simulatory defect could be patterned, such that dense arrays of fibers grew preferentially in the center of a grid-shaped pattern ( Figures 8B-8D). This work suggests that one can control fiber location and density by controlling seed initiator sites.
  • Figures 9A-9D show that mineral films composed of calcium phosphate can also be patterned by microcontact printing, and these films may also serve as potential seed substrates. In particular, these films are polycrystalline, and composed of a high density array of nanocrystals of hydroxyapatite, which can provide high surface energetics to stimulate fiber formation.

Abstract

The present invention pertains to mineral fibers useful as biomimetics of tissue, such as dental enamel and bone, and as filler in paper, paint, coatings, and plastic production. The present invention also concerns methods for producing mineral fibers by contacting an inorganic liquid-phase mineral precursor with a crystalline inorganic substrate under conditions permitting the inorganic liquid-phase mineral precursor to solidify and crystallize, compositions comprising mineral fibers, and methods for treating a tissue defect within a patient by applying mineral fibers to the site of the tissue defect.

Description

1 Docket No.: UF-304XC3
DESCRIPTION
FL3ROUS MINERALS. METHODS FOR THEIR PRODUCTION USING A SOLUTION-PRECURSOR-SOLLD MECHANISM. AND METHODS OF USE
Cross-Reference to Related Applications This application is a continuation-in-part application of U.S. Application No.
10/819,040, filed April 5, 2004, which is a continuation-in-part application of U.S.
Application No. 10/418,843, filed April 18, 2003, which claims the benefit of U.S. Provisional Application No. 60/373,801, filed April 18, 2002. U.S. Application No.
10/418,843 is also a continuation-in-part application of U.S. Application No. 10/691,002, filed October 22, 2003. Each of the foregoing applications are incorporated herein by reference in their entirety, including all nucleic acid sequences, amino acid sequences, figures, tables, and claims.
Government Support The subject invention was made with government support under a research project supported by the National Science Foundation Grant No. ECS-9986333. The government has certain rights in this invention.
Background of the Invention Synthetic bone graft material made to closely resemble natural bone would be a useful replacement for natural bone. Acceptable synthetic bone can avoid the problem of availability and harvesting of autogenous bone and the risks and complications associated with allograft bone, such as risks of infection, disease, and viral transmission. Natural bone is a composite material consisting of both water and organic and inorganic solid phases. Bone has a hard structure because its organic extracellular collagenous matrix is impregnated with inorganic crystals, principally hydroxyapatite (Caι0(PO )6(OH)2). Calcium and phosphate account for roughly 65% to 70% of the bone's dry weight. Collagen fibers compose approximately 95% of the extracellular matrix and account for 25% to 30% of the dry weight of bone. The organic material gives bone its flexibility and resilience, while the inorganic material gives bone its strength and 2 Docket No. : UF-304XC3 rigidity (modulus), and the organization of the two phases provides a high degree of toughness to the composite. A thorough review of bone structure from the angstrom level (mineral crystal) to the micron level (lamellae) has been presented (Weiner, S. et al. [1992] FASEB, 6:879-885). Surrounding the mineralized collagen fibers is a ground substance consisting of protein-polysaccharides, or glycosaminoglycans, primarily in the form of proteoglycan macromolecules. The glycosaminoglycans serve to cement together the various layers of mineralized collagen fibers. The individual collagen molecules self-assemble to form triple helices, which assemble into collagen fibrils, which then assemble into microscopic fibers. Within the packing of the collagen fibrils/fibers are distinct gaps, sometimes called hole zones. These hole zones are created by the staggered arrangement of tropocollagen molecules (triple helical rods), which leads to periodicity of the hole and overlap zones. Various models have been proposed where these hole zones are completely isolated from each other, or are contiguous and together form a groove. Within these hole zones, mineral crystals form. The mineral crystals in final form nucleate and grow within the fibrils (intrafibrillar mineralization), as well as into the interstitial spaces (interfibrillar mineralization) (Landis, WJ. et al. [1993] J. Struc Biol. 110:39-54). The mineral crystals in final form are a carbonated apatite mineral (dahllite), but initially may form as an amorphous calcium phosphate phase, which then transforms into the apatite (or possibly via an octacalcium phosphate precursor, which naturally forms plates). The apatite platelets of bone are of nanoscopic dimensions (only a few unit cells thick), and are densely packed into the type I collagen fibrils due to the intrafibrillar mineralization mechanism, and are well oriented with their c-axis (in the [001] direction) parallel to the long axis of the collagen fibrils. Because of the nature of the packing, the orientation of the collagen fibrils will determine the orientation of the mineral crystals (Martin, R.B. et al. [1998] "Skeletal Tissue Mechanics", Springer- Verlag Publishers, New York, N.Y.). There are numerous biocompatible artificial bone substitutes currently on the market. Of these substitutes, none successfully mimics the composite or microstructure of bone. For example, man-made ceramic composites have some of the desired properties of natural bone (such as matching of modulus), but are notoriously brittle and prone to cracking. By contrast, biological ceramics like bone and teeth resist cracking, 3 Docket No.: UF-304XC3 with a high toughness and stiffness. It is the nanostructured architecture that leads to mechanical properties that are unique to bone, which are not readily duplicated by polymers (which are not strong or stiff enough), or ceramics (which are brittle and lack toughness, and usually not bioresorbable). These mechanical properties are important because of the body's natural repair processes, in which bone is a living tissue and the cells respond according to the stresses they sense in their surrounding tissue (according to Wolffs Law). If an implant material has too high of a modulus (stiffness), the cells tend to resorb the surrounding bone due to the phenomenon of stress shielding (the stiffer material carries more of the load than the surrounding bone). A logical choice of materials for a synthetic bone substitute would be a collagen- hydroxyapatite composite; indeed, many have attempted to mineralize collagen in vitro, but the preparation of such a composite has been limited by the ability to achieve the high mineral loading that is attained biologically by intrafibrillar mineralization. An associated periodic contrast pattern is commonly observed by transmission electron microscopy (TEM) of collagen fibers (Carter, J.G. [1990] Skeletal Biomineralization: Patterns, Processes and Evolutionary Trends, Volume 1, Van Nostrand Reinhold Publishers, New York, N.Y.; Hodge, A.J. et al. [1963] "Recent studies with the electron microscope on ordered aggregates of the tropocollagen molecule", in Aspects of Protein Structure, Ramanchandran, G.N. (ed.), pp. 289-300, Academic Press, London, England; Katz, E.P. et al. [1989] Connect. Tissue Res., 21 :49-159). From tomographic imaging of naturally mineralizing turkey tendon (which is considered a model of secondary bone formation), there is evidence that the hydroxyapatite crystals first appear within the hole zones of collagen, and then spread throughout the fibrils, leading to the array of iso- oriented nanocrystals of highly organized hydroxyapatite [HAP] embedded within the organic matrix (Landis, W.J. et al. [1993] Structural Biology, 110:39-54; Landis, WJ. et al. [1991] Connect. Tissue Res., 25:181-196). Alternatively, there has been evidence that the collagen fibers contain an amorphous substance during the early stages of bone formation, referred to by Bonnuci as an "inorganic substance in bands" (ISBs), which then crystallizes into the more commonly observed platy crystals (Bonnuci, E. Calcification in Biological Systems [1992] CRC Press Boca Raton, FL). From a materials engineering perspective, the nanostructure of bone is intriguing and can be difficult to define. For example, it is not clear whether bone is more 4 Docket No.: UF-304XC3 accurately characterized as a polymer-fiber-reinforced ceramic-matrix composite or a ceramic-nanoparticle-reinforced polymer-matrix composite. The two phases are so intimately linked that the mechanical properties are distinctly different than ceramics or polymers, and therefore are difficult to reproduce. To date, scientists do not have a complete understanding of how bone is formed, even at this most basic level of structure. However, it is likely that the nanostructured architecture plays a role in the toughness of bone. Obviously, cellular control is important in biomineralization, and in the case of bone, helps to build its hierarchical structure (i.e., lamellae and osteons), but even the physicochemical mechanism for generating this nano-architecture has not been elucidated. Because intrafibrillar mineralization does not occur simply by attempting to crystallize collagen in vitro using supersaturated solutions of HAP (crystals only nucleate heterogeneously on the surface of the collagen fibers), it is generally assumed that nucleating proteins must be present within the gaps of the collagen fibrils. It is understood within the biomineralization community that acidic proteins can act as inhibitors to crystal nucleation or growth (Addadi, L. et al. [1987] Proc. Natl. Acad. Sci. USA, 84:2732-2736; Addadi, L. et al. [1992] Angew. Chem. Int. Ed. Engl. 31 :153-169; Mann, S. et al. [1983] Structure and Bonding, 54:125-174; Mann, S. et al. [1989] "Crystallochemical Strategies in Biomineralization" in Biomineralization- Chemical and Biochemical Perspectives. Mann, S., Webb, J., and Williams, R.J.P. (eds.), 33-62 (VCH Publishers, N.Y., New York)). In the case of crystal growth, it has been shown that selective inhibition of growth along stereospecific crystallographic planes can lead to a change in crystal morphology (Addadi, L. et al. [1985] Angew. Chem. Int. Ed. Engl., 24:466-485). In at least a few cases, acidic proteins have been shown to promote crystal nucleation (Addadi, L. et al. [1987] Proc. Natl. Acad. Sci. USA, 84:2732-2736; Greenfield, E.M. et al. [1984] Amer. ZooL, 24:925-932). It has also been shown that if the inhibitory action of a macromolecule is not complete, certain conditions lead to the induction (stabilization) of an amorphous liquid-phase precursor (Gower, L.B. et al. [2000] J. Crystal Growth, 210(4):719-734), which can have a profound consequence on crystal morphology since transformation of an amorphous precursor does not proceed via the same mechanism as traditional solution crystal growth (Mann, S. et al. [1989] "Crystallochemical Strategies in Biomineralization" in Biomineralization-Chemical arid Biochemical Perspectives. Mann, S., Webb, J., and Williams, R.J.P. (eds.), 33-62 (VCH 5 Docket No. : UF-304XC3
Publishers, N.Y., New York)). Certain features of this polymer-induced liquid-precursor (PILP) process suggest that this mechanism may occur during morphogenesis of calcium carbonate biominerals in invertebrates (Gower, L.A. [1997] "The Influence of Polyaspartate Additive on the Growth and Morphology of Calcium Carbonate Crystals," Doctoral Thesis, Department of Polymer Science and Engineering, University of Massachusetts at Amherst, 1-119). The present inventors have demonstrated that when the PILP phase is deposited onto an amorphous glass substrate, continuous thin films (~ 500 nm thick) of CaCO3 are formed (Gower L.A. et al, "Deposition of Calcium Carbonate Films by a Polymer- Induced Liquid-Precursor (PILP) Process" Journal of Crystal Growth, 2000, 210(4):719- 734). Organic substrates, such as type-I collagen, have also been used as substrates on which to deposit the PILP phase, resulting in intrafibrillarly mineralized organic/mineral composites (Olszta M.J. et al, [2003] Connective Tissue Research, 44:326-334; Olszta, M.J. et al, [2003] Calcified Tissue International, 72(5): 583-591). Neither of the previous substrates used were of a crystalline nature and, therefore, epitaxial interaction within the crystallization mechanism was not possible.
Brief Summary of the Invention The subject invention concerns a mineral fiber that is useful as a biomimetic substitute for bone and other tissues, such as dental enamel, and as filler in paper, paint, coatings, and plastics production. The mineral fiber of the present invention comprises a fibrous mineral phase having a high aspect ratio. The present invention also provides in vitro methods for making the mineral fibers, methods of using the mineral fibers to treat tissue defects, and compositions comprising the mineral fibers. In one embodiment, the method for producing the mineral fiber comprises contacting an inorganic liquid-phase mineral precursor with a crystalline inorganic substrate under conditions permitting the inorganic liquid-phase mineral precursor to solidify and crystallize, thereby forming the mineral fiber. Preferably, the formed mineral fiber exhibits a single crystalline birefringence and a single crystalline electron diffraction pattem. The crystalline inorganic substrate can comprise any of a variety of minerals, such as calcite rhombs or hydroxyapatite. The mineral can be nucleated on a solid surface. The crystalline inorganic substrate can comprise other mineral compositions 6 Docket No. : UF-304XC3 suitable for stimulating calcite nucleation from the PILP "flux" droplet. The PILP "flux" droplet preferably is comprised of inorganic mineral ions that are induced to phase segregate from the mineralizing solution by attraction to an anionic polymer, under conditions permitting formation of the inorganic liquid-phase mineral precursor. Preferably, the anionic polymer contacted with the mineralizing solution comprises at least one member selected from the group consisting of polyacrylic acid, polymethacrylic acid, sulfonated polymer, phosphorylated proteins or peptides, phosphorylated synthetic polymers, sulfated polysaccharides, sulfated glycoproteins, polyaspartic acid, polyglutamic acid, polyaspartate, polyvinyl phosphate, and polyvinyl phosphonate, or combinations of any of the foregoing, in either their acid or salt form. Preferably, the inorganic liquid-phase mineral precursor comprises at least one member selected from the group consisting of calcium phosphate, calcium carbonate, hydroxyapatite, strontium carbonate, barium carbonate, and calcium sulfate, strontium sulfate, calcium oxalate, magnesium-bearing calcium carbonate, and magnesium-bearing calcium phosphate. In other embodiments, the inorganic liquid-phase mineral precursor comprises at least one member selected from the group consisting of hydroxyapatite, octacalcium phosphate, tricalcium phosphate, carbonated hydroxyapatite, fluorinated hydroxyapatite, brushite, magnesium containing hydroxyapatite, dicalcium phosphate dihydrate, and amorphous calcium phosphate. Biologically active agents can be associated with the fibers of the present invention. For example, the biologically active agent can comprise at least one member selected from the group consisting of medicaments; vitamins; mineral supplements; substances used for the treatment, prevention, diagnosis, cure or mitigation of disease or illness; substances affecting the structure or function of the body; drugs; antimicrobial agents; antifungal agents; antibacterial agents; antiviral agents; antiparasitic agents; growth factors; angiogenic factors; anaesthetics; mucopolysaccharides; metals; cells; acid mucopolysaccharides; proteins; enzymes, peptides; and wound healing agents. In one embodiment, the fiber forming method further comprises forming the inorganic liquid-phase mineral precursor by combining calcium salt and an anionic polymer to form an aqueous solution, and reacting the aqueous solution with carbonate- containing vapor or solution (such as ammonium carbonate containing solution), or other counterion-containing vapors or solutions (such as phosphate, for calcium phosphate). 7 Docket No.: UF-304XC3
Optionally, the aqueous solution is reacted with the ammonium carbonate-containing vapor or solution, and the ammonium carbonate-containing vapor or solution is provided through the decomposition of at least one ammonium carbonate material selected from the group consisting of ammonium carbonate monohydrate, ammonium carbonate dihydrate, and ammonium carbamate. The fiber forming method can further involve forming the inorganic liquid-phase mineral precursor by combining calcium chloride and a combination of anionic polymers to form an aqueous solution, and reacting the aqueous solution with ammonium phosphate vapor or with a phosphate-containing solution, preferably in the presence of Tris-buffered saline (Tris hydroxymethyl aminomethane hydrochloride; Trizma base; sodium chloride), at a pH of about 7.4. However, one or more other buffers may be used, such as HEPES (N-2-hydroxyethylpiperazine-N'-2'ethanesulfonic acid); BIS-TRIS (bis- 2-hydroxyethyl-amino]tris-(hydroxymethyl)methane); CHES (2-
(cyclohexylaminoethanesulfonic acid); MOPS (2-(cyclohexylaminoethanesulfonic acid); and Phosphate buffered saline (PBS). In other embodiments, the method involves forming the inorganic liquid-phase mineral precursor by combining calcium salt and a combination of anionic polymers to form an aqueous solution, and reacting said aqueous solution with phosphate generated by enzymatic degradation of phosphate containing compounds. In other embodiments, the method involves forming the inorganic liquid-phase mineral precursor by combining calcium salt and ammonium phosphate, and a combination of anionic polymers to form an aqueous solution, in which precipitation is caused by at least one of the following conditions: a change of temperature, a change of pH, evaporation, or removal of crystallization inhibitor. The inorganic liquid-phase mineral precursor can be contacted with the crystalline inorganic substrate under various conditions. Preferably, the inorganic liquid-phase mineral precursor is contacted with the crystalline inorganic substrate in an aqueous solution at a temperature of 4° C or higher. In preferred embodiments, the contacting of the inorganic liquid-phase mineral precursor with the crystalline inorganic substrate involves contacting droplets of the inorganic liquid-phase mineral precursor with the crystalline inorganic substrate, wherein the droplets coalesce and solidify, and wherein the inorganic fiber is formed outward from the interface of the droplets and the crystalline 8 Docket No.: UF-304XC3 inorganic substrate. The droplets of inorganic liquid-phase mineral precursor include primary droplets that contact the crystalline inorganic substrate and secondary droplets that contact the primary droplets, wherein the secondary droplets extend the length of the inorganic fiber. Preferably, the secondary droplets extend the length of the inorganic fiber in a continuous fashion as a PILP phase is continuously generated through constant composition or batch replenishment techniques. Using the method of the invention, the inorganic liquid-phase mineral precursor can crystallize in an epitaxial orientation to the seed substrate, or may solidify first, crystallizing independently of the seed substrate. In one embodiment, the inorganic crystalline substrate is a film. In another embodiment, the inorganic liquid-phase mineral precursor comprises ions which precipitate into hydroxyapatite or other calcium phosphate phases, and the inorganic crystalline substrate comprises a hydroxyapatite film. Typically, the mineral fibers formed using the methods of the present invention have a high aspect ratio (length to diameter) in the range of about 5 (5:1) to 60 (60:1). In some embodiments, the fiber aspect ratio will be in the range of about 10 (10:1) to 60 (60:1). The formed fiber also has a mineral phase that is homogenously distributed throughout the width (cross-section) of the fiber (i.e., not a hollow cylinder). Typically, the mineral fibers formed have a diameter within the range of about 100 nm to 2 μm. Small individual fibers can be grown together in the same direction, thereby forming a fiber bundle of larger diameter (e.g., 100 nm to 1mm). In some embodiments, the mineral fiber of the present invention does not comprise a metal.
Brief Description of the Drawings Figures 1A-1D show a schematic representation of mineral fiber formation according to a method of the present invention. In Figure 1A, the polymer-induced liquid-precursor (PILP) phase is separated from solution in the form of nm-μm diameter droplets 10 of PILP phase. In Figure IB, these droplets then physisorb onto an existing crystalline (e.g., calcite) surface 20 and either solidify (• denoted by closed circle) or remain liquid (o denoted as an open circle). In Figure IC, subsequent droplets 10 that contact a solid primary droplet wick to the surface and form a film 30 surrounding the solid droplet. Secondary droplets that contact the primary liquid droplet coalesce with it. As subsequent droplets coalesce, primary droplets solidify, therefore pushing the fiber 40 9 Docket No. : UF-304XC3 away from the calcite surface (arrow denotes growth direction). In Figure ID, fiber growth continues as long as the liquid "bobble" 50 on the fiber head remains a liquid, continually forcing the fiber 40 away from the calcite surface (arrow denoted growth direction). Figures 2A-2C show micrographs demonstrating, respectively, classical calcite nucleation, thin films deposited via a polymer-induced liquid-precursor (PILP), and calcite overgrowth on calcite via traditional solution growth (in the absence of the PILP phase). Figures 3A-3C show micrographs of calcium carbonate fibers of the present invention extending from a crystalline substrate (calcite rhombs). Figures 4A-4K show a schematic representation of mineral fiber formation with integrated micrographs of calcite rhombs 60 nucleated on a surface 70 (forming a crystalline inorganic substrate), PILP droplets 10 adsorbing to a rhomb substrate 60 (Figures 4A-4E), and fibers 40 forming therefrom (Figures 4F-4K). Figures 5A-5C show micrographs of serpentine fibers produced by the mechanism of the present invention (which resemble serpentine fibers of semiconductor materials produced by the VLS and SLS mechanisms) (Figure 5A) and bobble tips on the fibers of the present invention (Figures 5B and 5C) resembling the "flux" droplets observed in VLS/SLS mechanisms. Figures 6A-6B shows that fibers can be formed in mineral systems other than calcium carbonate. Figure 6A shows a scanning electron micrograph of a dense mat of barium carbonate fibers which were stimulated to grow on the surface of a calcite rhomb. Figure 6B shows a transmission electron micrograph of one isolated fiber which is approximately 8 nm in diameter, and its corresponding electron diffraction pattem, demonstrating that the fiber, and is single crystalline, with spacings that match the witherite phase of BaCO3. Figures 7A-7D show a schematic representation of the microcontact printing technique used for micropatterning thin films of calcium carbonate or calcium phosphate. Self-Assembled Monolayers (SAMs) with controlled surface functionality are patterned using a PDMS "stamp" dabbed with an alkane thiol "ink". Figure 7A is an optical micrograph of the PDMS stamp with a micro-channel pattern. Figure 7B shows patterning of a SAM containing COOH and/or OH functional groups by micro-contact 10 Docket No.: UF-304XC3 printing the SAM on the Au surface. Figure 7C shows patterned surface is placed upside- down in a crystallization solution to avoid post-precipitates. Figure 7D shows that crystals preferentially nucleate on the SAMs with carboxylate functionality, and droplets of the amorphous precursor phase are deposited exclusively on the preferential SAM surface. Figures 8A-8F show calcitic films patterned via deposition of PILP phase on microcontact printed SAMs, which contained carboxylate-terminated alkane thiol on grid regions and methyl-terminated alkane thiol (or gold) on the remaining area (interior squares). Figure 8 A is an optical micrograph (with lst-order red waveplate) of calcite crystals shaped into a "grid-like" pattern. The reaction conditions were 12 mM to 24mM Ca-ion, 12 μg/ml PAA, at a temperature of at 4°C. Figure 8B shows a scanning electron micrograph of CaCO3 fibrous outgrowths formed at relatively high concentrations of anionic polymer (60 μg/ml polyacrylic acid), which leads to a secondary induction of PILP phase which collects at the edge of the pre-pattemed mineral film, and is stimulated to extend into fibrous outgrowths. Figure 8C shows a higher magnification view of some of the fibers of Figure 8B. Figure 8D shows dense fibrous arrays formed at the edges of some of the patterned mineral films, in which the fibers adhere into coherent outgrowths resembling "horsetails". Figure 8E shows dense fibrous mats formed under similar conditions, except for a higher calcium concentration of 24 mM Ca-ion. Figure 8F is a higher magnification view of Figure 8E, showing highly packed but relatively short mineral fibers. Figures 9A-9D show that hydroxyapatite can also be patterned into thin films, but with a high degree of surface texture that may be suitable to stimulate fiber formation. Figures 9A-9C show elemental mapping from Energy Dispersive Spectroscopy, demonstrating the composition of the hydroxyapatite mineral (Ca and Phosphorous absorption), which conforms to the micro-patterned self-assembled monolayer of COOH- (CH2)nSH. Figure 9D shows a higher magnification SEM image of a single stripe of patterned HA, showing that the film is polycrystalline, composed of nanoscopic platelets of hydroxyapatite. Figures 10A-10B show a comparison of calcite rhomb seed crystals grown by the solution method (Figure 10A) and gel method (Figure 10B), the latter of which leads to higher surface defect texture. Figure 10A shows a calcite seed crystal grown by classical 11 Docket No.: UF-304XC3 solution growth using a 12 mM calcium chloride dihydrate solution followed by subsequent vapor deposition of ammonium carbonate. Bar = 10 μm Figure 10B shows a gel grown calcite rhombohedral, using 0.5 M calcium chloride dihydrate in a 0.35 M silica gel and 0.25 M ammonium carbonate solution. Note the high degree of surface defect texture. Bar = 200 μm. Figure 10C shows calcite fibers grown on a solution grown calcite seed. In this case, the fibers exhibit what appears to be some type of iso- epitaxial relationship with the underlying seed crystal. Bar = 20 μm. Figure 10D shows a high density of fibrous calcite grown on the surface of a gel grown calcite seed crystal. An epitaxial relationship cannot be discerned for these crystals. Bar = 20 μm.
Detailed Description of the Invention The present invention pertains to mineral fibers and in vitro methods for producing mineral fibers utilizing an inorganic liquid-phase mineral precursor (PILP). According to the fiber forming method of the present invention, the PILP is contacted with a crystalline inorganic substrate under conditions permitting the PILP to solidify, crystallize, and extend away from the crystalline substrate, thereby forming the mineral fiber. According to the fiber forming methods of the present invention, the mineral fibers typically grow or extend in a substantially unidirectional manner, away from the crystalline substrate (thereby forming substantially linear mineral fibers). When there are fluctuations in the reaction, such as the temperature of the crystallizing solution, the fibers appear to grow in a serpentine manner, much like the serpentine growth exhibited by the fibers produced by the vapor-liquid-solid (VLS) mechanism or solution-liquid-solid (SLS) mechanism when the temperature is varied, as described by Trentler T.J. et al. (Trentler, T.J. et al. [1995] Science, 270(5243):1791-1794; Wagner, R.S. and W.C. Ellis, [1964] Applied Physics Letters, 4(5):89; Wagner, R.S. and W.C. Ellis, [1964] Journal of Metals, 16(9): 761). The inorganic liquid-phase mineral precursor utilized to form mineral fibers of the present invention can be produced using a variety of methods. For example, synthesis of a liquid-phase precursor of calcium carbonate has been described previously (Gower, L.B. and D.J. Odom [2000] J. Crystal Growth 210(4):719-734; Gower, L.A. [1997] "The Influence of Polyaspartate Additive on the Growth and Morphology of Calcium 12 Docket No.: UF-304XC3
Carbonate Crystals," Doctoral Thesis, Department of Polymer Science and Engineering, University of Massachusetts at Amherst, 1-119; Gower, L.A. and D.A. Tirrell [1998] J. Crystal Growth 191(1-2): 153-160), where vapor diffusion of the decomposition products of crushed ammonium carbonate (NH )2CO3 into a solution containing calcium chloride (CaCl2) is used to slowly raise the supersaturation of calcium carbonate; and one or more short-chain anionic polymer additives are added to induce the precursor mechanism. Alternative methods can be used to gradually raise the supersaturation of the crystallizing solution, including direct addition of a carbonate containing solution to the calcium containing solution; or the escape of carbon dioxide gas from a saturated calcium bicarbonate solution (which is produced by bubbling carbon dioxide into an aqueous solution containing the calcium carbonate salt). Supersaturation can also be raised using temperature, pH, or removal of inhibitory species. Similar methods can be used for the calcium phosphate system, although higher temperature (37° C) is more favorable for decomposition of ammonium phosphate (or any derivations of ammonium phosphate, such as ammonium phosphate dibasic). The phosphate counterion can be produced using enzymes that cleave phosphate-containing moieties, or through the degradation of phosphate containing phospholipid vesicles such as seen in Murphy and Messersmith (W. L. Murphy, P. B. Messersmith, Compartmental control of mineral formation: adaptation of a biomineralization strategy for biomedical use. Polyhedron, 2000, 19:357). Mineral- containing solutions, such as carbonate-containing or phosphate-containing solutions can have an effective concentration of mineral for fiber formation (such as 0.5 mM to 10 mM). According to the fiber formation method of the present invention, the crystalline substrate can then be contacted with the liquid-phase precursor of the inorganic mineral, such as calcium phosphate, calcium carbonate, hydroxyapatite, barium carbonate, strontium carbonate, calcium sulfate, calcium oxalate, calcium oxide, magnesium-bearing calcium carbonate or phosphate, or any polymorphs of these minerals. The crystalline inorganic substrate used in the fiber forming method permits epitaxial interaction within the crystallization mechanism. The crystalline substrate can comprise any of a variety of minerals, such as calcite rhombs or hydroxyapatite. It is not necessary that the crystalline substrate be a solid crystal. For example, the crystalline substrate can be a mineral film or thin film. For example, films comprising one or more 13 Docket No. : UF-304XC3 of CaCO , CaPO4, BaCO3, and SrCO3 can be used. Preferably, the film is a patterned film, which allows control of fiber location, morphology, and/or orientation. Fibers can be removed from the crystalline inorganic substrate by any suitable method. For example, the fibers can be removed from the substrate by centrifugation. One or more of a variety of anionic polymers, such as anionic short-chained polymers, can be utilized to initiate the amorphous liquid-phase mineral precursor, including different polymers and biological materials. Polyacrylic acid (PAA), polymethacrylates (PMA), sulfonated polymers, phosphorylated proteins, peptides and polymers, sulfated glycoproteins, polyaspartic acid, polyglutamic acid, polyaspartate, polyvinyl phosphate, and blends or copolymers of these materials, individually and in mixtures, can be utilized to induce the liquid-phase separation, for example. A range of polymer molecular weights can be suitable if the other variables of the crystallizing conditions are appropriately modified to generate the PILP phase. Preferably, molecular weights in the range of 2,000 to 15,000g/mol enhance the ability to induce formation of the precursor. The methods of the subject invention can be carried out under a variety of conditions. For example, in the case of an aqueous system, the fiber forming method can be carried out at a temperature of about 0° C to about 100° C. Preferably, the method is carried out at about 4° C or higher. More preferably, the method is carried out at about 37° C, to match physiological conditions. The method can be carried out at a pH in the range of about 5 to about 10. Preferably, the method is carried out at a pH of about 7.0 to about 7.8 and 1 atm. More preferably, the method is carried out at a pH of about 7.4. The type of reaction vessel or vessels utilized for producing the mineral fibers of the present invention, or their sizes, are not critical. Any vessel or substrate capable of holding or supporting the PILP and/or crystalline substrate so as to allow the reaction to take place can be used. Preferably, the supersaturation is gradually increased, allowing time for the anionic polymer to induce and stabilize the liquid-phase mineral precursor. It should be understood that, unless expressly indicated to the contrary, the terms "adding", "contacting", "mixing", "reacting", "combining" and grammatical variations thereof, are used interchangeable to refer to the mixture of reactants of the process of the present invention (e.g., anionic polymer additives, calcium-containing solution, and so forth), and the reciprocal mixture of those reactants, one with the other (i.e., vice-versa). 14 Docket No.: UF-304XC3 The mineral fibers formed using the methods of the present invention typically have a high aspect ratio (length to diameter) in the range of about 5 (5:1) to 60 (60:1). In some embodiments, the fiber aspect ratio will be in the range of about 10 (10:1) to 60 (60:1). The formed fiber has a mineral phase that is homogenously distributed throughout the width (cross-section) of the fiber (i.e., not a hollow cylinder). Typically, the mineral fibers formed have a diameter within the range of about 100 nm to 2 μm. Small individual fibers can be grown together in the same direction, thereby forming a fiber bundle having a larger diameter (e.g., 100 nm to 1 mm). If not desired, the mineral fiber of the present invention need not include a metal. The present invention further concerns a method of treating a patient having a tissue defect by applying mineral fibers of the subject invention (and compositions comprising the fibers) to the site of the tissue defect. As used herein, the term "patient" refers to any human or non-human animal suffering from a tissue defect. According to the method of the subject invention, a therapeutically effective amount of the fibers or composition can be applied at the site of a tissue defect to partially or fully restore structural integrity to the tissue. Once applied, the mineral fibers of the subject invention can function as a filler (or partial filler) or plug, to mend the tissue defect. The amount to be applied will depend upon the size and nature of the tissue defect, and the clinical outcome that is sought. The fibers can be applied within a composition in a malleable form, for example, as a paste or putty, such that the administered composition takes the shape of the bone defect. Alternatively, the composition can be molded pre-cast into a desired shape (such as the shape of the defect) using polymer composition molding methods known to those of ordinary skill in the art, and the molded composition can be administered as a solid or semi-solid article. Thus, the size, volume, thickness, and shape of the molded article can be controlled, as desired. The composition can be applied in particulate form. According to the method of the subject invention, the mineral fibers can be applied so that they directly contact existing tissue adjacent to, or defining, the tissue defect site, or the mineral fibers can be contacting another implant, or both. The composition of the subject invention (also referred to herein as constructs or fiber constructs or fibrous constructs) can be applied to the tissue defect site as a liquid. Once applied, with a syringe for example, the liquid composition can coagulate or cure ("set") shortly after application to form a solid. 15 Docket No.: UF-304XC3 The mineral fibers of the subject invention (and compositions comprising the fibers) can be used as a vehicle for the in situ delivery of biologically active agents. The biologically active agents incorporated into, or included as an additive within, the fibers of the subject invention can include, without limitation, medicaments, growth factors, vitamins, mineral supplements, substances used for the treatment, prevention, diagnosis, cure or mitigation of disease or illness, substances which affect the stmcture or function of the body, or drugs. The biologically active agents can be used, for example, to facilitate implantation of the mineral fibers into a patient and to promote subsequent integration and healing processes. The active agents include, but are not limited to, antifungal agents, antibacterial agents, anti-viral agents, anti -parasitic agents, growth factors, angiogenic factors, anaesthetics, mucopolysaccharides, metals, cells, and other wound healing agents. Because the processing conditions can be relatively benign (physiological temperature and pH), biologically active agent such as live cells can be incorporated into fiber constructs during their formation, or subsequently allowed to infiltrate the fibers or compositions through tissue engineering techniques. As indicated above, cells can be seeded onto and/or within the mineral fiber constructs of the present invention. Likewise, tissues such as cartilage can be associated with the mineral fibers prior to implantation within a patient. Examples of such cells include, but are not limited to, bone cells (such as osteoclasts, osteoblasts, and osteocytes), blood cells, epithelial cells, neural cells (e.g., neurons, astrocytes, and oligodendrocytes), and dental cells (odontoblasts and ameloblasts). Seeded cells can be autogenic, allogenic, or xenogenic. Seeded cells can be encapsulated or non- encapsulated. Examples of antimicrobial agents that can be used in the present invention include, but are not limited to, isoniazid, ethambutol, pyrazinamide, streptomycin, clofazimine, rifabutin, fluoroquinolones, ofloxacin, sparfloxacin, rifampin, azithromycin, clarithromycin, dapsone, tetracycline, erythromycin, cikprofloxacin, doxycycline, ampicillin, amphotericine B, ketoconazole, fluconazole, pyrimethamine, sulfadiazine, clindamycin, lincomycin, pentamidine, atovaquone, paromomycin, diclarazaril, acyclovir, trifluorouridine, foscamet, penicillin, gentamicin, ganciclovir, iatroconazole, miconazole, Zn-pyrithione, and silver salts, such as chloride, bromide, iodide, and periodate. 16 Docket No.: UF-304XC3 Growth factors that can be incorporated into the fibers and compositions of the present invention include, but are not limited to, bone growth factors (e.g., BMP, OP-1) basic fibroblast growth factor (bFGF), acidic fibroblast growth factor (aFGF), nerve growth factor (NGF), epidermal growth factor (EGF), insulin-like growth factors 1 and 2 (IGF-1 and IGF-2), platelet-derived growth factor (PDGF), tumor angiogenesis factor (TAF), vascular endothelial growth factor (VEGF), corticotropin releasing factor (CRF), transforming growth factors alpha and beta (TGF-α and TGF-/3), interleukin-8 (IL-8), granulocyte-macrophage colony stimulating factor (GM-CSF), the interleukins, and the interferons. Other agents that can be incorporated into the fibers or compositions of the subject invention include acid mucopolysaccharides including, but not limited to, heparin, heparin sulfate, heparinoids, dermatan sulfate, pentosan polysulfate, chondroitin sulfate, hyaluronic acid, cellulose, agarose, chitin, dextran, carrageenin, linoleic acid, and allantoin. Proteins that can be incorporated into, or included as an additive within, the fibers or compositions of the subject invention include, but are not limited to, collagen (including cross-linked collagen), fibronectin, laminin, elastin (including cross-linked elastin), osteopontin, osteonectin, bone sialoproteins (Bsp), alpha-2HS-glycoproteins, bone Gla-protein (Bgp), matrix Gla-protein, bone phosphoglycoprotein, bone phosphoprotein, bone proteoglycan, protolipids, bone morphogenetic protein, cartilage induction factor, platelet derived growth factor and skeletal growth factor, enzymes, or combinations and biologically active fragments thereof. Other proteins associated with other parts of human or other mammalian anatomy can be incorporated or included as an additive, including proteins associated with cartilage, such as chondrocalcining protein, proteins associated with dentin, such as phosphoryin, glycoproteins and other Gla proteins, or proteins associated with enamel, such as amelogenin and enamelin. Agents incorporated into the fibers or compositions of the subject invention may or may not facilitate or enhance osteoinduction. Adjuvants that diminish an immune response can also be used in conjunction with the fibers or compositions of the subject invention. The biologically active agents can first be encapsulated into microcapsules, microspheres, microparticles, microfibers, reinforcing fibers and the like to facilitate mixing and achieving controlled, extended, delayed and/or sustained release. 17 Docket No. : UF-304XC3
Encapsulating the biologically active agent can also protect the agent against degradation during formation of the fibers or compositions of the invention. Additionally, the biologically active agents can be pendantly attached to the PILP phase or the formed fibers. The attachment can be facilitated through covalently linking the agent to inorganic phase, or through the use of hydrogen bonding. In preferred embodiments of the invention, the biologically active agent is controllably released into a mammal when the fibers or composition of the invention is implanted into a mammal, either through degradation in the aqueous environment, or more preferably, due to bioresorption relying on the time scale resulting from cellular remodeling. The fibers or fibrous constructs of the subject invention can be used to replace an area of discontinuity in the tissue in the mammalian body. The area of discontinuity in the tissue can be as a result of trauma, disease, genetic defect, tumor, or surgery, for example. The compositions of the subject invention can be formulated into a variety of shapes suitable for its function as a tissue implant, such as a plate, pin, rod, screw, anchor, tack, arrow, staple, button, or other regular or irregular shape. The composition of the present invention can be formulated as a three-dimensional scaffold and, optionally, seeded with one or more cell types for implantation within a patient. For example, a hydroxyapatite (HAP) containing PILP can be used to produce fibrous HAP for dental applications. Teeth are composed of various biomineral layers, with the enamel layer being composed of fibrous HAP. Using the mineral fiber forming method of the present invention, the HAP containing PILP can be deposited onto HAP films to produce an ordered array of fibrous crystals for dental applications. The term "tissue defect", as used herein refers to any tissue deficient region, such as a void, gap, recess, or other discontinuity in the hard or soft tissues. The tissue defect can be artificially or naturally established, and can occur due to disease or trauma, for example. Thus, the tissue defect can occur as a consequence of pathologic, inflammatory, or tumor diseases, surgical interventions, congenital defects, or bone fractures, and the like. Typically, tissue defects in dental applications will be on or within the gum or jaw of the patient's mouth. For example, in the case of certain diseases, such as tumors, the tissue defect is artificially established by removing the tumor tissue. Thus, according to the method of the subject invention, the mineral fibers or compositions containing the 18 Docket No.: UF-304XC3 mineral fibers can be applied, for example, to repair periodontal defects, for craniofacial reconstruction, joint reconstruction, fracture repair, to conduct orthopedic surgical procedures, and spinal fusion, for example. The term "tissue defect" is also intended to include anatomical sites where augmentation to a tissue feature is desired by the patient in the absence of disease or trauma, such as in elective cosmetic surgery. Thus, the "defect" can be one that is subjectively perceived by the patient, and where augmentation of the bone deficient region is desired. The term "polymorph", as used herein, refers to inorganic minerals that are similar in chemical composition but have different crystal structures. The terms "comprising", "consisting of, and "consisting essentially of are defined according to their standard meaning and may be substituted for one another throughout the instant application in order to attach the specific meaning associated with each term. As used in this specification and the appended claims, the singular forms "a", "an", and "the" include plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to "a fiber" includes more than one such fiber, and the like. Reference to "an anionic polymer" includes more than one such polymer, and the like. In addition to their therapeutic applications, the mineral fibers of the present invention may be used as filler in plastics, paint, coatings, and paper production. For example, calcium carbonate is used in a wide range of plastics as a filler, most notably PVC piping. Calcium carbonate fibers of the present invention are particularly useful in these applications because they have high aspect ratios that enhance reinforcement (modulus and strength), and their small size provide excellent surface area for adhesion to the matrix phase. In addition, calcite has a Moh's hardness of 3. In contrast, aragonite, which naturally forms needlelike crystals and is currently the only "fibrous" calcium carbonate available for filler, has a Moh's hardness of 4, making it slightly harder than calcite. Thus, using a fibrous calcite mineral phase would result in less wear on machinery. In addition, unlike the fibers of the present invention, the needle-like shape of aragonite crystals are not in the form of individual fibers, but are packed within spherulitic bundles which are not readily separated as isolated fibers for manipulation into the above composites. 19 Docket No. : UF-304XC3
All patents, patent applications, provisional applications, and publications referred to or cited herein, supra or infra, are incorporated by reference in their entirety, including all figures and tables, to the extent they are not inconsistent with the explicit teachings of this specification. It should be understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application.
Materials and Methods Polymer-Induced Liquid-Precursor (PILP) Process. The preparation of a PILP phase has been described previously (Gower, L.B. and D.J. Odom [2000] J. Crystal
Growth, 210(4):719-734; Gower, L.A. [1997] "The Influence of Polyaspartate Additive on the Growth and Morphology of Calcium Carbonate Crystals," Doctoral Thesis,
Department of Polymer Science and Engineering, University of Massachusetts at
Amherst, 1-119; Gower, L.A. and D.A. Tirrell [1998] J. Crystal Growth, 191(1-2): 153-
160). The general process introduces the anionic polymer into an aqueous salt solution which is slowly raised in supersaturation. One common method for raising supersaturation is to slowly introduce one of the ionic species, for example using a modified vapor diffusion technique developed by Addadi et al. (Addadi, L. et al. [1985]
Proc. Natl. Acad. Sci. USA, 82:4110-4114), in which ammonium carbonate (NH4)2CO3 vapor, produced by decomposition of its powder, diffuses into a solution containing calcium chloride CaCl2 and the anionic polymeric additive. This multistage process is illustrated by the formula: (NH4)2CO3(v) CaCl2(aq) +P(D)(aq) » CaCO3-P(D)-H2O(l) -» CaCO3(s) Stage I Stage II Precursor Deposition Precursor Transformation Alternatively, calcium phosphate (CaP) readily forms an amorphous gel prior to crystallization, which may be contacted with the inorganic crystalline substrate.
6 mM CaCl2(aq) + 200 μg/ml PVP(aq) + 200 μg/ml P(D)(aq) + (NH4)2HPO4(v) -» CaP 20 Docket No.: UF-304XC3
Typically, the crystal products are deposited onto a thin glass coverslip (22 mm
D.) that is placed in the crystallizing solution, which can then be examined by polarized light microscopy (including in situ examination with ultra-long-working-distance objectives), or gold coated for scanning electron microscopy (SEM). The exact concentration of the reactants can vary. Formation of Inorganic Crystalline Substrate. Substrate crystals were synthesized in three different manners, two of which provided calcite crystals of typical rhombohedral habit, but which differed in size and defect texture, and one which provides CaCO3 thin films. For the first set of experiments, micron sized calcite rhombs (20-40 μm) were deposited on glass slides via a vapor diffusion method (Addadi, L., Moradian, J., Shay, E., Maroudas, N. G. and Weiner, S., Proc. Natl. Acad. Sci. U.S.A., 1987, 84:2732-2736). For comparison, larger, millimeter sized calcite rhombs were grown through a metasilicate gel method. For the first type, glass substrates (22 mm diameter microscope coverslips) were placed into small petri dishes containing 3 ml of a 24 mM CaCl »H2O (SIGMA) solution, and this crystallizing solution was placed in an enclosed chamber (e.g., a desiccator) containing small vials of freshly crushed ammonium carbonate. The carbonate powder decomposes into a vapor (CO2 and NH3) at room temperature, which slowly diffuses into the calcium solution, providing a means for gradually raising the supersaturation of CaCO3. The larger 0.5 mm calcite crystals were fabricated in a gel medium through a controlled chemical reaction method. A sodium metasilicate gel was prepared using 0.5 M CaCl2*H2O (SIGMA) in a 0.35 M Na2O3Si«9H2O (SIGMA) solution, which was allowed to set in 15 mm dia/127 mm long glass test tubes overnight until gelation. Subsequently, 0.1 M ammonium carbonate solution was added to each test tube and then covered with parafilm. The ammonium carbonate was allowed to diffuse into the gel over a period of 1 month, at which time large calcite crystals were gently removed with tweezers and rinsed several times with deionized water. The larger calcite crystals were analyzed using EDS in order to assure no Si remained on the surface of the crystals. It was observed that the gel grown rhomb crystals led to a higher fiber density. A much greater defect texture can be seen on the surface of the gel grown rhomb (due to inclusion of gel impurity), which apparently stimulated more fibers to nucleate and grow. 21 Docket No. : UF-304XC3
Figure 10A shows a representative gel grown seed, and Figure 10B shows a higher fiber density on the surface of this type of seed crystal. Without being bound by theory, the present evidence suggests that the surface texture of the seed crystal is important for stimulating fiber formation. This may arise due to accumulation of a sufficient amount of PILP droplets to form a "flux" droplet. It appears that small PILP droplets rapidly solidify when adsorbed to a solid substrate, but the present inventors have observed that thicker accumulations of PILP droplets remain fluidic. The fluidity of the precursor is presumed to be critical to fiber formation; therefore, this ability to generate a fluidic "flux" droplet may be enhanced with the appropriate surface texture that accumulates some quantity of fluidic precursor phase. Based on the bobbles on the fiber tips, a desirable size for a "flux" droplet appears to be in the range of approximately 100 nanometers to approximately five microns in size. In one embodiment, the flux droplet is in the range of approximately 100 nanometers and 3 microns in size. The literature suggests that the defect texture of calcite crystals can be easily controlled, thereby providing a means for increasing the fiber density. In addition to fiber quantity, modulating the surface texture of the seed substrate can be used to regulate fiber morphology, such as size (length and diameter) and quality (surface roughness and internal crystallinity), as well as location (for patterning fiber bundles or arrays). Arrays of fibers can be formed in a random or organized format (rows, columns, etc.). One manner to make calcite surfaces tailored to have specific surface density characteristics, can be made following Teng (H. H. Teng, Controls by saturation state on etch pit formation during calcite dissolution. Geochimica Et Cosmochimica Ada 68, 253 (Jan, 2004)). Briefly, Teng found that by cleaving a large optical-quality Iceland spar (calcite) with a razor blade, to expose the {10-14} face, he could study the surface dissolution kinetics via the addition of solutions undersaturated with respect to CaCO . He concluded that when the saturation index Ω > 0.541 (Ω is defined as the ratio of ionic activity product to solubility product), no etch pit formation was observed, and dissolution occurred at existing steps. When Ω was decreased to 0.541-0.410, pits began to appear and with continuous decrease in saturation allowed for pit density to increase with continued dissolution at step edges. Finally, when Ω was lowered below ~0.007, there was a sharp increase in pit density. 22 Docket No. : UF-304XC3 These observations suggest that the defect texture of calcite crystals can be easily controlled, thereby increasing the fiber density. In addition to etch pits, other options for accumulating the PILP phase can include pattern scratches or indents on the surface (such as from a nano or micro indenter), or pattern substrate films with edges that collect PILP droplets, or impurity incorporation into the seed crystal, which leads to higher surface defects (as shown by the gel grown calcite rhomb in Figure 10B). Impurities can be incorporated into the crystals during their formation, such as other inorganic ions or molecular compounds, including polymeric additives. Controlling fiber morphology, fiber orientation, and fiber density on the substrate is particularly useful for making patterned arrays or for building a composite structure. For example, control of fiber orientation will be particularly useful for fabrication of nanowires, circuits, etc. High fiber density (and, therefore, high surface areas) would be useful for use in catalysis reactions. The third method for accumulating PILP phase in accordance with the present invention is to make crystalline films (such as crystalline calcium carbonate thin films), which can accumulate PILP phase at the edges, for fiber deposition substrates, utilizes the method described by Gower (Gower, L.B. and D.J. Odom J. Crystal Growth, 2000, 210(4):719-734) as a component. In this method, glass substrates (22 mm diameter microscope coverslips) were placed into small petri dishes containing 3 ml of a 24 mM CaCl2«H2O (SIGMA) solution, and various amounts of anionic polymer additives. This crystallizing solution was placed in an enclosed chamber (e.g., a desiccator) containing small vials of freshly crushed ammonium carbonate. The resultant film is crystalline calcium carbonate. The mineral films can also be patterned in order to template the location of fiber formation by using the soft lithography technique of microcontact printing (Aizenberg, j. et al. Nature, 1999, 398:495-498). Self-assembled monolayers (SAMs) of controlled surface functionality can be "stamped" onto substrates to regulate the location where the mineral precursor will deposit (or where solution crystals nucleate, as shown by Aizenberg [Aizenberg, J. et al. Nature, 1999, 398:495-498]). For example, alkane thiol groups can be patterned onto gold-coated substrates, and chosen to have endgroups containing charged, polar, or non-polar head groups, which preferentially stimulate mineral formation on the monolayers with charged or more polar headgroups (Kim, Y.-Y. and L.B. Gower "Formation of complex non-equilibrium morphologies of 23 Docket No. : UF-304XC3 calcite via biomimetic processing" Materials Research Society, San Francisco, MRS, 2003). Likewise, silanol chemistry can be used to pattern surfaces (such as glass) with silane coupling agents of controlled surface functionality. Formation of Fibrous Crystals. The substrate crystals were introduced into the crystallizing system by placing the glass coverslips which had nucleated the 20 - 40 μm calcite rhombs (or contained 3 to 4 of the larger gel grown rhombs or films) in the bottom of a small petri dish filled with 3 ml of a 12 mM calcium chloride dihydrate solution, containing 0.24 mM MgCl2*6H2O or SrCl2»6H O, along with 200 μg/mL of polyacrylic acid (5,100 M.W., SIGMA) to induce the PILP process (Gower, L.B. and Odom, D.J. J. Crystal Growth, 2000, 210:719-734). The Mg2+ and Sr2+, which are routinely found in naturally occurring calcite morphologies, were added because we have determined that they enhance the PILP process (inhibit solution crystal nucleation). Ammonia and CO2(g) was delivered to the sample solutions via the decomposition of crushed ammonium carbonate powder in the same manner as described above for synthesizing substrate crystals. Each of the sample solutions and ammonium carbonate vials were covered with parafilm, into which small holes were punched in order to slowly raise the supersaturation of the calcium carbonate in solution. All components of the reaction were then placed in an enclosed chamber, which allowed diffusion of the carbonate into the solution. Control experiments, containing no polymer, were performed alongside each experiment. For further characterization, the coverslips containing the small rhomb substrate crystals (or individual large gel-grown calcite rhombs) were carefully removed from solution with tweezers and rinsed with ultrapure H2O and then with ethanol (by gently dipping coverslip in a rinse beaker to avoid dislodging the fragile fibers) in order to remove any soluble salts. The glass slides were then examined using an Olympus BX- 60 optical microscope in transmission mode, using crossed polars and an optional first- order-red wave plate. Polarized Optical Light Microscopy (POM) Analysis. Samples were examined on the glass slides in transmission mode using an Olympus BX60 polarized optical microscope with first-order red wave-plate. The wave-plate allows one to observe both amorphous and crystalline phases, which is quite useful for examining crystallization reactions that proceed via precursor mechanisms. In this case, it was also useful for examining the crystallographic orientation of the fibers. Under plane polarized light 24 Docket No.: UF-304XC3
(PPL), a crystal will appear dark (extinct) under crossed polars when its vibration directions are oriented parallel to one of the polars (indicated as "p" and "a" for polarizer and analyzer direction, respectively). When a gypsum plate is inserted, the crystal in the extinct position will exhibit the same retardation color as the magenta background. Maximum birefringence will occur when the crystal is rotated 45° from the analyzer and polarizer due to constructive interference of the light waves. Calcite is an optically negative material, therefore when the slow vibration direction of the wave-plate (indicated as "sd" double arrow) is parallel with the slow axis of the calcite (indicated by short arrow in NE comer), the combined vibrations will destmctively interfere and the fiber will appear blue (a fall in interference color determined from Michel Levy chart). Conversely, the yellow color in the opposite quadrants indicates the slow ray of the crystal is parallel to the slow direction of the accessory plate. This type of analysis allows one to identify if there is a uniform orientation of the crystallographic axes within irregular shaped crystals, such as the fibers described here. Scanning Electron Microscopy (SEM) Analysis. The samples were dried overnight, fixed to an aluminum stub using carbon paste or double-sided copper tape and then Au/Pd coated. The samples were then examined with either a JEOL 6400 SEM or a JEOL 6335F FEGSEM instrument, both equipped with energy dispersive spectrometers (EDS), at an accelerating voltage of 15kV. Transmission Electron Microscopy (TEM) Analysis. In order to examine the fibrous calcium carbonate, the samples were first scratched with a razor blade to dislodge some of the fibers from the rhomb substrate. A small aliquot of ethanol was then dispensed onto the scratched area and immediately drawn up using a micropipette. The removed aliquot was then dropped onto a 200 mesh copper TEM grid coated with thin layers of Formvar and amorphous carbon. The grid was air-dried and subsequently sputter coated with amorphous carbon for stability. The sample was examined on a JEOL 200cx or 201 OF transmission electron microscope at 200 kV in brightfield (BF) and selected area diffraction (SAD) modes.
Example 1 — Calcium Carbonate Fibers Fibrous calcium carbonate (CaCO3/calcite) crystals 100-800 nm in diameter were produced at temperatures as low as 4° C. The calcium carbonate fibers were deposited 25 Docket No.: UF-304XC3 onto calcite rhombs using a mineralization process involving the inclusion of short- chained anionic polymers (e.g., polyaspartic acid or polyacrylic acid) to a supersaturated calcium carbonate system to induce an amorphous liquid-phase precursor. This latter process, documented in the literature, is known as the polymer-induced liquid-precursor (PILP) process. In previous reports, the present inventors have demonstrated that when the PILP phase is deposited onto an amorphous glass substrate, continuous thin films (-500 nm thick) of CaCO3 are formed (Gower, L.B. and D.J. Odom [2000] J. Cryst. Grow., 210(4):719-734). Organic substrates, such as type-I collagen, have also been used on which to deposit the PILP phase, resulting in intrafibrillarly mineralized organic/mineral composites (Olszta, M.J. et al., [2003] Conn. Tiss. Res., 44:326-334; Olszta, M.J. et al., [2003] Calcified Tissue International, 72(5):583-591). Because these substrates were not of a crystalline nature, there was no possible epitaxial interaction involved in the crystallization mechanism. In the present experiment, crystalline substrates were used which were synthesized by nucleating 20-40 μm calcite rhombs onto glass substrates. When no polymer was used to induce the PILP process, epitaxial overgrowth of calcite roughened the surface of the existing calcite seeds. CaCO3 PILP droplets preferentially deposited onto the calcite rhombs instead of the glass, but did not form completely continuous films on the faces of the calcite. On a majority of the rhombs, fibrous crystals, which exhibited a single crystalline birefringence, were observed growing from each of the faces. The fibrous crystals were identified as calcite using electron diffraction, and although the diffraction patterns were single crystalline in nature, brightfield (BF) transmission electron microscopy (TEM) images of the majority of fibers showed distinct grains, suggesting that they are polycrystalline with all of the grains aligned in the same orientation. Scanning electron microscopy (SEM) shows the surface of the fibers sometimes appear to be covered in iso-oriented calcite rhombs. Because the electron diffraction pattern shows distinct spots, strongly indicative of single crystals, it seems likely that these polycrystalline features are actually microfacets arising from surface reorganization of the energetically unfavorable curved crystals surfaces. In addition, using SEM, enlarged bobbles were observed on the growing ends of the fibers. The observation of single crystalline fibers growing off of the crystalline inorganic substrates, in combination with the enlarged bobbles at the ends of the fibers, 26 Docket No. : UF-304XC3 indicates that the process may bear some similarity to existing high temperature crystal growth mechanisms, such as the vapor-liquid-solid (VLS) and solution-liquid-solid (SLS), used to produce nanofibrous semiconductor materials. These processes function through the use of a metal nuclei, which is heated above its melting temperature and placed in an appropriate atmosphere (once the metal has melted, it is referred to as a flux). In the VLS mechanism, a high melting temperature metal is set on a silicon substrate and placed in a vapor atmosphere, whereas in the SLS, a low melting temperature metal is placed in an organometallic solution. Once these metals melt (creating the flux droplet), crystallizing constituents in the atmosphere (vapor or liquid) begin to diffuse into the flux. As a supersaturation of these constituents is reached, crystallization occurs either on the solid surface (VLS) with epitaxial orientation, or with the lowest energy plane forming (SLS) at the flux wall. As long as the temperature is kept above the melting temperature of the metal flux, and the concentration of the crystallizing constituent within the flux droplet is kept constant, the fibers continue to grow, restricted to one dimensional growth by the dimension of the flux droplet containing the reactants. Using the growth mechanisms as a model, it was hypothesized that the calcite fibers disclosed herein are grown in a similar manner, but without a molten metal flux. Instead, they can be formed in an aqueous solution at low temperature. The amorphous liquid-precursor (PILP) droplets begin to deposit on the mineral face and either solidify or remain partially liquid-like. If the primary droplets solidify, subsequent droplets wick to the side of these droplets and form a film. On the other hand, primary droplets that remain liquid-like can further coalesce with subsequent droplets, at which time the primary droplets in contact with the crystalline surface begin to solidify and crystallize. The top droplet remains a liquid while the bottom becomes solid, thus forcing the fiber outward from the crystalline substrate. As long as the leading "flux" droplet (which appears as a bobble on the end of the fiber) remains as a liquid, the fiber will continue to grow. The mechanism is demonstrated in the schematic of Figures 1A-1D and Figures 4A-4K. The present inventors have named this process the solution-precursor-solid (SPS) mechanism. It is similar to the VLS and SLS mechanisms in the sense that a "flux" droplet restricts crystal growth to one dimension to form a fiber; yet it differs in that the "flux" droplet is not a molten metal, but instead is comprised of a PILP phase, which enables fibers to be formed in aqueous solutions and at much lower temperatures (such as 27 Docket No.: UF-304XC3 room temperature and below). Likewise, epitaxy may not be necessary in the proposed SPS mechanism, because solidification of the PILP phase may also force the flux droplet outward causing one-dimensional growth, even though the initial solidified phase may be amorphous. Figures 3A-3C and 5A-5C show micrographs of calcium carbonate fibers of the present invention.
Example 2 — Hydroxyapatite (HA) Fibers Enamel, the hardest known vertebrate tissue, is comprised of "rods" of hydroxyapatite tightly packed together in an organized array. Enamel and dentin share a unique starting point, the dentino-enamel junction (DEJ), with the enamel growing away from the DEJ to serve as the mastication surface, and the dentin growing in towards the pulp. While researchers agree that dentine is the first to appear, there is still debate as to whether the enamel epitaxially nucleates from the dentine surface (G. W. Bernard, Ultrastructural observations of initial calcification in dentin and enamel. Journal of Ultras tructure Research 41, 1 (1972).; E. J. Reith, Early stage of amelogenesis as observed in molar teeth of Yorun rats. Journal of Ultrastructure Research 17, 503 (1967).; P. Bodier-Houlle, P. Steuer, J. M. Meyer, L. Bigeard, F. J. G. Cuisinier, High- resolution electron-microscopic study of the relationship between human enamel and dentin crystals at the dentinoenamel junction. Cell and Tissue Research 301, 389 (September, 2000); T. Diekwisch, B. J. Berman, S. Gentner, H. C. Slavkin, Initial enamel crystals are not associated with mineralized dentin. Journal of Dental Research 73, 112 (1994)). Additionally, there are reports that there are poorly crystalline or amorphous regions between dentin and enamel (P. Bodier-Houlle, P. Steuer, J. M. Meyer, L. Bigeard, F. J. G. Cuisinier, High-resolution electron-microscopic study of the relationship between human enamel and dentin crystals at the dentinoenamel junction. Cell and Tissue Research 301, 389 (September, 2000)). These observations led the present inventors to believe that hydroxyapatite fibers resembling enamel can be recreated using a liquid- amorphous mineral precursor deposited upon hydroxyapatite substrates. Hydroxyapatite crystals can be formed by a variety of syntheses. One is to nucleate crystals on glass slides via direct addition of ion reactants, such as solutions containing calcium chloride and potassium phosphate. Preferably, a supersaturated solution of calcium phosphate is formed by addition of equal volumes of 9 mM CaCl2 and 4.2 mM of 28 Docket No.: UF-304XC3
K2HPO4 in tris-buffer, to a final concentration of 4.5 mM CaCl2 and 2.1M of K2HPO . The solution is mixed at room temperature and the crystallization performed at 37°C and at a pH of 7.4. The CaPO PILP process involves adding Poly(Aspartic acid- sodium salt), at concentrations to induce the liquid-phase amorphous mineral precursor (in the range of 5 to 100 μg/ml). The glass slides with the hydroxyapatite crystals are placed in the mineralizing solution containing the anionic polymer, allowing the CaPO4 PILP phase to deposit onto the CaP seed crystals.
Example 3 - Barium Carbonate Fibers Fibrous barium carbonate (BaCO /witherite) crystals 50-100 nm in diameter and several microns in length were produced on calcium carbonate seeds at temperatures as low as 4° C (Figure 6A). The barium carbonate fibers were deposited onto calcite rhombs or films using the polymer-induced liquid-precursor (PILP) process, outlined in Example 1. In this experiment, 20-40 μm calcite rhombs on glass substrates were used, as in
Example 1. When no polymer was used to induce the PILP process, witherite aggregates heterogeneously nucleated on the calcite seed surface. When polymer was added, fibrous crystals were observed growing from some of the faces. The fibrous crystals were identified as witherite using electron diffraction (Figure 6B). Brightfield (BF) transmission electron microscopy (TEM) images of the majority of fibers shows they were bent, possibly as a result of twinning. The bent, or fluidic, nature of the fibers was confirmed using SEM. It is also possible that these bends arise from fluidic flow of the liquid precursor phase during fiber formation. Given the similarity in reaction conditions, it is presumed that the barium carbonate fibers nucleate and grow by the SLS process described in Example 1. Figures 6A and 6B show barium carbonate fibers of the present invention. This work with BaCO shows that different minerals can be stimulated to form by this SPS mechanism, suggesting that it could be a more generalized mechanism applicable to a variety of inorganic phases. In addition, this work shows that a crystallographic phase can be produced that differs from the phase comprising the seed substrate, suggesting that an epitaxial match is not needed to induce fiber formation. 29 Docket No.: UF-304XC3 A different type of "seed" substrate was found to stimulate fiber formation. In this case, the substrate was composed of thin films of calcium carbonate, which appeared to stimulate fibers to grow at the edges of the films, which are high in surface energy, similar to a crystal defect. Figures 7A-7D show a schematic of the microcontact printing technique used to pattern the calcite film shown in Figure 8A. Because the initial filmlike mineral can be patterned using the soft lithography technique of microcontact printing, the location of the simulatory defect could be patterned, such that dense arrays of fibers grew preferentially in the center of a grid-shaped pattern (Figures 8B-8D). This work suggests that one can control fiber location and density by controlling seed initiator sites. Figures 9A-9D show that mineral films composed of calcium phosphate can also be patterned by microcontact printing, and these films may also serve as potential seed substrates. In particular, these films are polycrystalline, and composed of a high density array of nanocrystals of hydroxyapatite, which can provide high surface energetics to stimulate fiber formation.

Claims

30 Docket No.: UF-304XC3 ClaimsWhat is claimed is:
1. A method for producing a mineral fiber, said method comprising contacting an inorganic liquid-phase mineral precursor with a crystalline inorganic substrate under conditions permitting the inorganic liquid-phase mineral precursor to solidify and crystallize, thereby forming the mineral fiber.
2. The method according to claim 1, wherein the formed mineral fiber exhibits a single crystalline birefringence.
3. The method according to claim 1 or claim 2, wherein the formed mineral fiber exhibits a single crystalline electron diffraction pattern.
4. The method according to any of claims 1 to 3, wherein the crystalline inorganic substrate comprises a mineral.
5. The method according to any of claims 1 to 4, wherein the crystalline inorganic substrate comprises calcite rhombs.
6. The method according to any of claims 1 to 4, wherein the crystalline inorganic substrate comprises a mineral film.
7. The method according to claim 6, wherein the film is a patterned film.
8. The method according to claim 6, wherein the film comprises at least one member selected from the group consisting of CaCO3, CaPO4, BaCO3, SrCO3.
9. The method according to claim 5, wherein the calcite rhombs are nucleated on a solid surface.
31 Docket No. : UF-304XC3 10. The method according to any of claims 1 to 4, wherein the crystalline inorganic substrate comprises crystals of hydroxyapatite.
11. The method according to any of claims 1 to 4, wherein the inorganic liquid-phase mineral precursor forms a PILP flux droplet prior to solidification and crystallization, and wherein the crystalline inorganic substrate comprises other mineral compositions suitable for stimulating calcite nucleation from the PILP flux droplet.
12. The method according to any of claims 1 to 4, wherein the inorganic liquid-phase mineral precursor comprises an inorganic mineral that can be generated by a liquid-phase amorphous-mineral precursor.
13. The method according to any of claims 1 to 4, wherein said method further comprises forming the inorganic liquid-phase mineral precursor by contacting an anionic polymer with a mineralizing solution under conditions permitting formation of the inorganic liquid-phase mineral precursor.
14. The method according to claim 13, wherein the anionic polymer comprises at least one member selected from the group consisting of polyacrylic acid, polymethacrylic acid, sulfonated polymer, phosphorylated proteins or peptides, phosphorylated synthetic polymers, sulfated polysaccharides, sulfated glycoproteins, polyaspartic acid, polyglutamic acid, polyaspartate, polyvinyl phosphate, and polyvinyl phosphonate, or combinations of any of the foregoing.
15. The method according to any of claims 1 to 4, wherein the inorganic liquid-phase mineral precursor comprises at least one member selected from the group consisting of calcium phosphate, calcium carbonate, hydroxyapatite, strontium carbonate, barium carbonate, and calcium sulfate, strontium sulfate, calcium oxalate, magnesium-bearing calcium carbonate, and magnesium-bearing calcium phosphate.
16. The method according to any of claims 1 to 4, wherein the inorganic liquid-phase mineral precursor comprises at least one member selected from the group consisting of 32 Docket No.: UF-304XC3 hydroxyapatite, octacalcium phosphate, tricalcium phosphate, carbonated hydroxyapatite, fluorinated hydroxyapatite, brushite, magnesium containing hydroxyapatite, dicalcium phosphate dihydrate, and amorphous calcium phosphate.
17. The method according to any of claims 1 to 16, wherein said method further comprises associating a biologically active agent with the fiber.
18. The method according to claim 17, wherein the biologically active agent comprises at least one member selected from the group consisting of medicaments; vitamins; mineral supplements; substances used for the treatment, prevention, diagnosis, cure or mitigation of disease or illness; substances affecting the stmcture or function of the body; d gs; antimicrobial agents; antifungal agents; antibacterial agents; antiviral agents; antiparasitic agents; growth factors; angiogenic factors; anaesthetics; mucopolysaccharides; metals; cells; acid mucopolysaccharides; proteins; enzymes, peptides; and wound healing agents.
19. The method according to any of claims 1 to 4, wherein said method further comprises forming the inorganic liquid-phase mineral precursor by combining calcium salt and an anionic polymer to form an aqueous solution, and reacting the aqueous solution with a carbonate-containing vapor or solution, or a phosphate-containing vapor or solution.
20. The method according to claim 19, wherein the aqueous solution is reacted with the carbonate-containing vapor or solution, and wherein the carbonate-containing vapor or solution is provided through the decomposition of at least one ammonium carbonate material selected from the group consisting of ammonium carbonate monohydrate, ammonium carbonate dihydrate, and ammonium carbamate.
21. The method according to claim 19, wherein the aqueous solution is reacted with the phosphate vapor or solution, and wherein the phosphate vapor or solution is provided through the decomposition of at least one ammonium phosphate material selected from the group consisting of ammonium phosphate monobasic, ammonium phosphate dibasic.
33 Docket No. : UF-304XC3 22. The method according to any of claims 1 to 4, wherein said method further comprises forming the inorganic liquid-phase mineral precursor by combining calcium chloride and a combination of anionic polymers to form an aqueous solution, and reacting the aqueous solution with phosphate-containing vapor or solution.
23. The method according to any of claims 1 to 4, wherein said method further comprises forming the inorganic liquid-phase mineral precursor by combining calcium chloride and a combination of anionic polymers to form an aqueous solution, and reacting said aqueous solution with a phosphate containing solution.
24. The method according to any of claims 1 to 4, wherein said method further comprises forming the inorganic liquid-phase mineral precursor by combining calcium salt and a combination of anionic polymers to form an aqueous solution, and reacting said aqueous solution with phosphate generated by enzymatic degradation of phosphate containing compounds.
25. The method according to any of claims 1 to 4, wherein said method further comprises forming the inorganic liquid-phase mineral precursor by combining calcium salt and ammonium phosphate, and a combination of anionic polymers to form an aqueous solution, in which precipitation is caused by at least one of the following conditions: a change of temperature, a change of pH, evaporation, or removal of crystallization inhibitor.
26. The method according to any of claims 1 to 25, wherein said contacting of the inorganic liquid-phase mineral precursor with the crystalline inorganic substrate is carried out in an aqueous solution.
27. The method according to any of claims 1 to 26, wherein said contacting of the inorganic liquid-phase mineral precursor with the crystalline inorganic substrate is carried out at a temperature of 4° C or higher.
28. The method according to any of claims 1 to 27, wherein said contacting of the inorganic liquid-phase mineral precursor with the crystalline inorganic substrate comprises 34 Docket No.: UF-304XC3 contacting droplets of the inorganic liquid-phase mineral precursor with the crystalline inorganic substrate, wherein the droplets coalesce and solidify, and wherein the inorganic fiber is formed outward from the interface of the droplets and the crystalline inorganic substrate.
29. The method according to claim 28, wherein the droplets of inorganic liquid-phase mineral precursor comprise primary droplets that contact the crystalline inorganic substrate and secondary droplets that contact the primary droplets, and wherein the secondary droplets extend the length of the inorganic fiber.
30. The method according to claim 28, wherein the droplets of inorganic liquid-phase mineral precursor comprise primary droplets that contact the crystalline inorganic substrate and secondary droplets that contact the primary droplets, and wherein the secondary droplets extend the length of the inorganic fiber in a continuous fashion as a PILP phase is continuously generated through constant composition or batch replenishment techniques.
31. The method according to any of claims 1 to 4, wherein the inorganic liquid-phase mineral precursor comprises hydroxyapatite, and wherein the inorganic crystalline substrate comprises a hydroxyapatite film.
32. The method according to any of claims 1 to 4, wherein the formed fiber has an aspect ratio in the range of about 5 (5:1) to 60 (60:1).
33. The method according to any of claims 1 to 32, wherein the formed fiber comprises a mineral phase that is homogenously distributed throughout the width of the fiber.
34. The method according to any of claims 1 to 33, wherein the inorganic liquid- phase mineral precursor crystallizes in an epitaxial orientation.
35. The method according to any of claims 1 to 34, wherein the inorganic liquid- phase mineral precursor does not comprise a metal flux.
35 Docket No. : UF-304XC3 36. The method according to any of claims 1 to 35, wherein the inorganic liquid- phase mineral precursor forms a PILP flux droplet prior to solidification and crystallization, wherein the PILP flux droplet is approximately 100 nanometers to approximately 5 micrometers in size.
37. The method according to any of claims 1 to 4, wherein the crystalline inorganic substrate has a surface texture that induces formation of a PILP flux droplet prior to solidification and crystallization.
38. The method according to any of claims 1 to 4, wherein the crystalline inorganic substrate has a surface with patterned defects.
39. The method according to claim 38, wherein the patterned defects are scratches or indents.
40. The method according to any of claims 1 to 4, wherein the crystalline inorganic substrate is a film with edges that induce formation of a PILP flux droplet at the edges prior to solidification and crystallization.
41. The method according to any of claims 1 to 4, wherein the crystalline inorganic substrate has a surface with patterned defects, and wherein the patterned defects act as a template, causing formation of a plurality of mineral fibers as an organized array.
42. The method according to any of claims 1 to 4, wherein the crystalline inorganic substrate has a surface with defects caused by the presence of impurities, and wherein the surface defects cause accumulation of a PILP flux droplet at the defects.
43. The method according to any of claims 1 to 4, wherein the mineral fiber comprises barium carbonate.
44. A mineral fiber produced by the method of any of claims 1 to 43.
36 Docket No. : UF-304XC3 45. A mineral fiber comprising a mineral phase.
46. The mineral fiber of claim 45, wherein said mineral phase is homogenously distributed throughout the width of said fiber.
47. The mineral fiber of claim 45 or 46, wherein said mineral fiber has an aspect ratio in the range of about 5 (5:1) to 60 (60:1).
48. The mineral fiber of any of claims 45 to 47, wherein said mineral fiber has a diameter within the range of about 100 nm and about 1 mm.
49. The mineral fiber of any of claims 45 to 48, wherein said mineral fiber does not comprise a metal.
50. A pharmaceutical composition comprising an effective amount of a mineral fiber and a pharmaceutically acceptable carrier.
51. A pharmaceutical composition comprising a mineral fiber produced by the method of any of claims 1 to 43, and a pharmaceutically acceptable carrier.
52. A method for treating a tissue defect within a patient, said method comprising applying an effective amount of a mineral fiber to the site of the tissue defect, wherein the mineral fiber comprises a mineral phase.
53. The method of claim 52, wherein the mineral fiber is applied within a pharmaceutical composition comprising the fiber and a pharmaceutically acceptable carrier.
54. The method of claim 53, wherein the pharmaceutical composition is an injectable liquid, a film, a malleable putty, a malleable paste, a particulate, or a molded or preformed solid.
37 Docket No.: UF-304XC3 55. The method of claim 52, wherein the mineral fiber is formulated and applied as a scaffold seeded with cells.
56. The method of claim 52, wherein the mineral fiber is applied as a biomimetically prepared fibrous constmct that mimics dental enamel.
57. The method of claim 56, wherein the fibrous construct has been grown in an aqueous based system mimicking the biological mechanism of enamel formation to form organized arrays of mineral fibers.
58. A method for treating a tissue defect within a patient, said method comprising applying an effective amount of a mineral fiber to the site of the tissue defect, wherein the mineral fiber is produced according to the method of any of claims 1 to 43.
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