Assembled non-random foams

• US 20050112397A1
• Filed: 07/23/2004
• Published: 05/26/2005
• Est. Priority Date: 07/24/2003
• Status: Active Grant

• Current Assignee: Tecomet, Inc.
• Original Assignee: Tecomet, Inc.
• Inventors: Amrich, Mark P., Lynch, Robert, Rolfe, Jonathan L., Cairns, Robert, Buturlia, Joseph A., Gerry, Michael
• Granted Patent: US 7,208,222 B2
• Time in Patent Office: Days
• US Class Current: 428/593
• CPC Class Codes: A61B 17/562 Implants for placement in joint gaps without restricting joint motion, e.g. to reduce arthritic pain
• CPC Class Codes: A61B 17/7044 also having plates, staples or washers bearing on the vertebrae
• CPC Class Codes: A61B 17/8605 Heads, i.e. proximal ends projecting from bone
• CPC Class Codes: A61B 17/866 Material or manufacture
• CPC Class Codes: A61B 17/8695 Washers surrounding screw head in plate hole A61B17/8047, between bone plate and bone A61B17/8028
• CPC Class Codes: A61C 8/0012 characterised by the material or composition, e.g. ceramics, surface layer, metal alloy use of specific materials A61K6/00
• CPC Class Codes: A61F 2/0811 Fixation devices for tendons or ligaments
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2/32 for the hip
• CPC Class Codes: A61F 2/34 Acetabular cups
• CPC Class Codes: A61F 2/36 Femoral heads ; Femoral endoprostheses
• CPC Class Codes: A61F 2/367 Proximal or metaphyseal parts of shafts trochanteric devices connected to said proximal parts A61F2/30739
• CPC Class Codes: A61F 2/3676 Distal or diaphyseal parts of shafts
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/3877 Patellae or trochleae
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/4081 Glenoid components, e.g. cups
• CPC Class Codes: A61F 2/4241 for hands, e.g. fingers
• CPC Class Codes: A61F 2/442 : Intervertebral or spinal discs, e.g. resilient non-disc-shaped intervertebral inflatable pockets A61F2/441; non-disc-shaped intervertebral fusion implants A61F2/4455
• CPC Class Codes: A61F 2/4455 : for the fusion of spinal bodies, e.g. intervertebral fusion of adjacent spinal bodies, e.g. fusion cages intervertebral discs A61F2/442
• CPC Class Codes: A61F 2/447 : substantially parallelepipedal, e.g. having a rectangular or trapezoidal cross-section
• CPC Class Codes: A61F 2/481 : Acoustic or audible means
• CPC Class Codes: A61F 2002/087 : Anchor integrated into tendons, e.g. bone blocks, integrated rings
• CPC Class Codes: A61F 2002/0888 : Anchor in or on a blind hole or on the bone surface without formation of a tunnel
• CPC Class Codes: A61F 2002/30004 : the prosthesis being made from materials having different values of a given property at different locations within the same prosthesis
• CPC Class Codes: A61F 2002/30009 : differing in fibre orientations
• CPC Class Codes: A61F 2002/30011 : differing in porosity
• CPC Class Codes: A61F 2002/30014 : differing in elasticity, stiffness or compressibility
• CPC Class Codes: A61F 2002/30062 : (bio)absorbable, biodegradable, bioerodable, (bio)resorbable, resorptive
• CPC Class Codes: A61F 2002/30069 : elastomeric
• CPC Class Codes: A61F 2002/30113 : circular
• CPC Class Codes: A61F 2002/30125 : elliptical or oval
• CPC Class Codes: A61F 2002/3013 : figure-"8"- or hourglass-shaped
• CPC Class Codes: A61F 2002/30143 : hexagonal
• CPC Class Codes: A61F 2002/30149 : pentagonal
• CPC Class Codes: A61F 2002/30151 : rhomboidal or parallelogram-shaped
• CPC Class Codes: A61F 2002/30153 : rectangular
• CPC Class Codes: A61F 2002/30154 : square
• CPC Class Codes: A61F 2002/30199 : Three-dimensional shapes
• CPC Class Codes: A61F 2002/30224 : cylindrical
• CPC Class Codes: A61F 2002/30227 : arched, domed or vaulted
• CPC Class Codes: A61F 2002/30235 : tubular, e.g. sleeves
• CPC Class Codes: A61F 2002/30261 : parallelepipedal
• CPC Class Codes: A61F 2002/3028 : polyhedral different from parallelepipedal and pyramidal
• CPC Class Codes: A61F 2002/30293 : Cylindrical body made by spirally rolling up a sheet or a strip around itself
• CPC Class Codes: A61F 2002/30299 : umbrella-shaped or mushroom-shaped
• CPC Class Codes: A61F 2002/30451 : soldered or brazed or welded
• CPC Class Codes: A61F 2002/30563 : having elastic means or damping means, different from springs, e.g. including an elastomeric core or shock absorbers
• CPC Class Codes: A61F 2002/30593 : hollow
• CPC Class Codes: A61F 2002/30649 : Ball-and-socket joints
• CPC Class Codes: A61F 2002/30677 : Means for introducing or releasing pharmaceutical products, e.g. antibiotics, into the body
• CPC Class Codes: A61F 2002/3071 : Identification means; Administration of patients
• CPC Class Codes: A61F 2002/30785 : parallel
• CPC Class Codes: A61F 2002/30878 : with non-sharp protrusions, for instance contacting the bone for anchoring, e.g. keels, pegs, pins, posts, shanks, stems, struts
• CPC Class Codes: A61F 2002/30892 : parallel
• CPC Class Codes: A61F 2002/30906 : shot- sand- or grit-blasted
• CPC Class Codes: A61F 2002/30915 : made of a stack of bonded perforated sheets, grids or wire meshes
• CPC Class Codes: A61F 2002/3092 : having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30925 : etched
• CPC Class Codes: A61F 2002/30929 : having at least two superposed coatings
• CPC Class Codes: A61F 2002/30934 : Special articulating surfaces
• CPC Class Codes: A61F 2002/30952 : using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/30955 : using finite-element analysis
• CPC Class Codes: A61F 2002/30957 : using a positive or a negative model, e.g. moulds
• CPC Class Codes: A61F 2002/30967 : Diffusion bonding
• CPC Class Codes: A61F 2002/30971 : Laminates, i.e. layered products
• CPC Class Codes: A61F 2002/342 : the outer shell having circumferential protrusions parallel to the equatorial plane, e.g. circumferential fins or wings
• CPC Class Codes: A61F 2002/3611 : Heads or epiphyseal parts of femur
• CPC Class Codes: A61F 2002/4018 : Heads or epiphyseal parts of humerus
• CPC Class Codes: A61F 2002/448 : comprising multiple adjacent spinal implants within the same intervertebral space or within the same vertebra, e.g. comprising two adjacent spinal implants
• CPC Class Codes: A61F 2210/0004 : bioabsorbable
• CPC Class Codes: A61F 2220/0058 : soldered or brazed or welded
• CPC Class Codes: A61F 2230/0006 : circular
• CPC Class Codes: A61F 2230/0008 : elliptical or oval
• CPC Class Codes: A61F 2230/001 : Figure-8-shaped, e.g. hourglass-shaped
• CPC Class Codes: A61F 2230/0017 : Angular shapes
• CPC Class Codes: A61F 2230/0019 : rectangular
• CPC Class Codes: A61F 2230/0021 : square
• CPC Class Codes: A61F 2230/0063 : Three-dimensional shapes
• CPC Class Codes: A61F 2230/0069 : cylindrical
• CPC Class Codes: A61F 2230/0082 : parallelepipedal
• CPC Class Codes: A61F 2230/0091 : helically-coiled or spirally-coiled, i.e. having a 2-D spiral cross-section
• CPC Class Codes: A61F 2230/0093 : Umbrella-shaped, e.g. mushroom-shaped
• CPC Class Codes: A61F 2250/0014 : having different values of a given property or geometrical feature, e.g. mechanical property or material property, at different locations within the same prosthesis
• CPC Class Codes: A61F 2250/0018 : differing in elasticity, stiffness or compressibility
• CPC Class Codes: A61F 2250/0023 : differing in porosity
• CPC Class Codes: A61F 2250/0024 : made from both porous and non-porous parts, e.g. adjacent parts
• CPC Class Codes: A61F 2250/0028 : differing in fibre orientations
• CPC Class Codes: A61F 2250/0089 : coded with symbols, e.g. dots, numbers, letters, words
• CPC Class Codes: A61F 2310/00017 : Iron- or Fe-based alloys, e.g. stainless steel
• CPC Class Codes: A61F 2310/00023 : Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00029 : Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• CPC Class Codes: A61F 2310/00047 : Aluminium or Al-based alloys
• CPC Class Codes: A61F 2310/00059 : Chromium or Cr-based alloys
• CPC Class Codes: A61F 2310/00089 : Zirconium or Zr-based alloys
• CPC Class Codes: A61F 2310/00095 : Niobium or Nb-based alloys
• CPC Class Codes: A61F 2310/00125 : Hafnium or Hf-based alloys
• CPC Class Codes: A61F 2310/00131 : Tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00149 : Platinum or Pt-based alloys
• CPC Class Codes: A61F 2310/00155 : Gold or Au-based alloys
• CPC Class Codes: A61F 2310/00179 : Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00293 : containing a phosphorus-containing compound, e.g. apatite
• CPC Class Codes: A61F 2310/00329 : Glasses, e.g. bioglass
• CPC Class Codes: A61F 2310/00407 : Coating made of titanium or of Ti-based alloys
• CPC Class Codes: A61F 2310/00485 : Coating made of zirconium or Zr-based alloys
• CPC Class Codes: A61F 2310/00634 : Coating made of zirconium oxide or hydroxides
• CPC Class Codes: A61F 2310/0073 : Coating or prosthesis-covering structure made of compounds based on metal carbides
• CPC Class Codes: A61L 27/04 : Metals or alloys
• CPC Class Codes: A61L 27/56 : Porous materials, e.g. foams or sponges
• CPC Class Codes: Y10T 428/1234 : Honeycomb, or with grain orientation or elongated elements in defined angular relationship in respective components [e.g., parallel, inter- secting, etc.]
• CPC Class Codes: Y10T 428/24273 : including aperture
• CPC Class Codes: Y10T 428/24298 : Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
• CPC Class Codes: Y10T 428/24322 : Composite web or sheet
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249961 : With gradual property change within a component

Abstract

A porous structure having a plurality of bonded sheets each sheet having at least one aperture that partially overlaps an aperture of at least one other sheet. A method of producing a porous structure including stacking a plurality of sheets each sheet having a multiplicity of apertures, and bonding each sheet to its adjoining sheet. An open-pore network structure having a multiplicity of sheets each having a repeatable pattern. At least a portion of each sheet is bonded to the web of an adjacent sheet. The porous area of at least one of the sheets is askew to the porous area of at least another of the sheets. An open-pore structure having a multiplicity of bonded sheets, each sheet having a repeatable pattern defining a multiplicity of perforations, and a plurality of apertures defined by the repeatable pattern, the apertures extending through the perforations of at least two adjacent plates.

Claims

1. A cancellous structure comprising:

a plurality of bonded sheets each sheet having at least one aperture having a transverse dimension and a longitudinal dimension that is no more than approximately four times the transverse dimension, the at least one aperture of a first sheet partially overlapping the at least one aperture of at least one other sheet.

2. The cancellous structure of claim 1 wherein the transverse dimension and the longitudinal dimension are sufficient to promote the ingrowth of tissue.

3. The cancellous structure of claim 1 wherein the transverse dimension and the longitudinal dimension are each between approximately 10 microns and 5000 microns.

4. The cancellous structure of claim 1 wherein the transverse dimension and the longitudinal dimension are each between approximately 100 microns and 450 microns.

5. The cancellous structure of claim 1 wherein the apertures of the sheets are aligned to produce a plurality of tortuous pores.

6. The cancellous structure of claim 1 having a porosity between 5% and 90%.

7. The cancellous structure of claim 1 wherein each of the plurality of sheets has a porosity of between approximately 5% and approximately 90%.

8. The cancellous structure of claim 1 wherein one of the plurality of sheets has a porosity of between approximately 5% and approximately 90%.

9. The cancellous structure of claim 1 wherein the apertures are defined by a regular repeatable pattern.

10. The cancellous structure of claim 9 wherein the regular repeatable pattern is pseudorandom.

11. The cancellous structure of claim 1 wherein the apertures of at least one sheet are arranged in substantially the same regular repeating pattern as another sheet.

12. The cancellous structure of claim 1 wherein a first of the plurality of sheets is aligned askew to a second of the plurality of sheets.

13. The cancellous structure of claim 1 wherein the first sheet of a plurality of sheets is aligned offset to a second of the plurality of sheets.

14. The cancellous structure of claim 1 comprising a refractory metal.

15. The cancellous structure of claim 13 wherein the refractory metal is selected from the group consisting of titanium, tantalum, zirconium, oxidized zirconium, hafnium, platinum, rhodium, niobium and alloys thereof.

16. The cancellous structure of claim 1 comprising a material selected from the group consisting of gold, aluminum, stainless steel and alloys thereof.

17. The cancellous structure of claim 1 comprising a material selected from the group consisting of cobalt-chrome or chrome-cobalt-molybdenum alloys.

18. The cancellous structure of claim 1 wherein the structure is porous in three-dimensions.

19. The cancellous structure of claim 1 wherein a least one aperture extends to an edge of the structure.

20. The cancellous structure of claim 1 further comprising at least one edge that is substantially solid.

21. The cancellous structure of claim 1 having a differential porosity.

22. The cancellous structure of claim 20 wherein the differential porosity is a stepped differential porosity.

23. The cancellous structure of claim 1 having a graduated porosity.

24. The cancellous structure of claim 1 wherein a plurality of webs define the apertures and adjacent sheets have different aperture-to-web ratios.

25. The cancellous structure of claim 1 wherein a plurality of webs define the apertures and each of the plurality of sheets has an aperture-to-web ratio of between approximately 95:

1 and 1;

20.

26. The cancellous structure of claim 1 wherein the webs are serpentine.

27. The cancellous structure of claim 1 wherein a first sheet has a thickness that is different from a second sheet.

28. The cancellous structure of claim 1 wherein the plurality of apertures a plurality of webs define the pores and adjacent sheets have differing aperture-to-web ratios.

29. The cancellous structure of claim 1 wherein the plurality of sheets are of a preformed shape.

30. The cancellous structure of claim 1 having a preformed shape configured to connect to a solid material.

31. A composite comprising the cancellous structure of claim 1 and a solid material.

32. The composite of claim 31 wherein the cancellous structure and the solid material are of substantially similar materials.

33. The composite of claim 31 wherein the cancellous structure and the solid material are of substantially dissimilar materials.

34. The cancellous structure of claim 1 having a preformed shape configured to connect to a component of a medical implant.

35. The cancellous structure of claim 34 wherein the medical implant is an orthopedic implant.

36. The cancellous structure of claim 34 wherein the medical implant is a spinal implant.

37. The cancellous structure of claim 34 wherein the medical implant is a dental implant.

38. The cancellous structure of claim 34 wherein the medical implant is a digital implant.

39. The cancellous structure of claim 34 wherein the medical implant is an augmentation implant.

40. The cancellous structure of claim 34 wherein the medical implant is an articulating implant.

41. The cancellous structure of claim 1 further comprising at least one barrier layer.

45. The cancellous structure of claim 1 wherein a first of the plurality of sheets is bonded to a second of the plurality of sheets and the first of the plurality of sheets and the second of the plurality of sheets are different materials.

46. The cancellous structure of claim 1 wherein a first of the plurality of sheets is textured and a second of the plurality of sheets that is not textured.

47. The cancellous structure of claim 1 wherein at least one of the plurality of sheets is textured.

48. The cancellous structure of claim 47 wherein the at least one textured sheet is configured to effect the surface roughness of the cancellous structure.

49. The cancellous structure of claim 1 further comprising a tissue engaging surface.

50. The cancellous structure of claim 1 configured to accept bone ingrowth.

51. The cancellous structure of claim 1 further comprising a polymer engaging structure.

52. The cancellous structure of claim 1 further comprising a compliant surface engaging region.

53. The cancellous structure of claim 1 configured to form a medical implant.

54. The cancellous structure of claim 1 configured to form a component of a medical implant.

55. The cancellous structure of claim 1 wherein at least one of the plurality of sheets is polymer.

56. The cancellous structure of claim 55 wherein the polymer is selected from the group consisting of UHMWPE, PTFE, HDPE, hydroxyapetite, PEEK, polyglycolic acid, polylactic acid, polyoxyethylenes, and co-polymers thereof.

43. The cancellous structure of claim 43 wherein the barrier layer is semi-solid sheet.

42. The cancellous structure of claim 43 wherein the barrier layer is a solid sheet.

44. The cancellous structure of claim 43 wherein the barrier layer is a textured sheet

57. A cancellous structure comprising:

a plurality of stacked sheets, each sheet having a multiplicity of webs and apertures, at least one web of each sheet being bonded to at least one web of an adjacent sheet, the bonded webs configured to form at least one structural element and the apertures of adjacent sheets having an alignment configured to form a plurality of tortuous pores throughout the cancellous structure.

58. The cancellous structure of claim 57 configured to approximate at least one predetermined mechanical property.

59. The cancellous structure of claim 57 wherein the at least one of the structural elements is a post.

60. The cancellous structure of claim 57 wherein the at least one of the structural elements is a beam.

61. The cancellous structure of claim 57 wherein at least one of the structural elements is a scaffold.

62. A tissue engaging structure comprising:

a plurality of stacked bonded sheets having a plurality of apertures, the apertures of the stacked sheets having an alignment configured to form a plurality of tortuous pores through the plurality of stacked sheets, the plurality of apertures being dimensioned to accommodate tissue ingrowth.

63. An orthopedic implant comprising:

a first and second tissue engaging bone substitute component each having a plurality of sheets with a multiplicity of webs defining a multiplicity of apertures, the plurality of sheets being bonded together to form an open pore structure;

an elastic component at least partially infused within a portion of the first and second tissue engaging bone substitute components.

64. The orthopedic implant of claim 63 wherein elastic component is polymer.

65. The orthopedic implant of claim 63 wherein the polymer is selected from the group consisting of UHMWPE, PTFE, HDPE, hydroxyapetite, PEEK, polyglycolic acid, polylactic acid, polyoxyethylenes and co-polymers thereof

66. A method of producing a cancellous structure comprising:

stacking a plurality of sheets each sheet having a multiplicity of apertures,

bonding each sheet to its adjoining sheet.

67. The method of claim 66 wherein the bonding is chemical bonding.

68. The method of claim 66 wherein the bonding is mechanical bonding.

69. The method of claim 66 wherein the bonding is physical bonding.

70. The method of claim 66 wherein the bonding is diffusion bonding.

71. The method of claim 66 wherein the bonding is soldering.

72. The method of claim 66 wherein the bonding is brazing.

73. The method of claim 66 further comprising:

post-processing the bonded sheets.

74. The method of claim 73 wherein the post-processing comprises etching.

75. The method of claim 73 wherein the post-processing comprises increasing the porosity of the cancellous structure.

76. The method of claim 66 wherein the multiplicity of apertures are arranged in a regular repeating pattern and the stacking further comprises:

orienting the regular repeating pattern of a first of the plurality of sheets askew to the regular repeating pattern of a second of the plurality of sheets.

77. The method of claim 66 wherein the sheets comprise a refractory metal.

78. The method of claim 77 wherein the refractory metal is selected from the group consisting of titanium, tantalum, zirconium, oxidized zirconium, hafnium, platinum, rhodium, niobium and alloys thereof.

79. The method of claim 66 wherein the plurality of sheets comprise a material selected from the group consisting of gold, aluminum, stainless steel and alloys thereof

80. The method of claim 66 wherein the plurality of sheets comprise a material selected from the group consisting of cobalt-chrome or chrome-cobalt-molybdenum alloys.

81. The method of claim 66 wherein the stacking comprises assembling the sheets in a fixture that is not flat.

82. The method of claim 66 wherein the stacking comprises assembling the sheets in a rolled fixture.

83. The method of claim 66 wherein the stacking comprises assembling the sheets in a mold.

84. The method of claim 66 wherein the post processing includes infusing at least a portion of the plurality of sheets with polymer.

85. The method of claim 84 wherein the polymer is selected from the group consisting of UHMWPE, PTFE, HDPE, hydroxyapetite, PEEK, polyglycolic acid, polylactic acid, polyoxyethylenes, and co-polymers thereof.