Oxidized zirconium on a porous structure for bone implant use

• US 20060020346A1
• Filed: 08/05/2005
• Published: 01/26/2006
• Est. Priority Date: 12/16/2003
• Status: Active Grant

• Current Assignee: Gordon Hunter, Vivek Pawar
• Original Assignee: Gordon Hunter, Vivek Pawar
• Inventors: Hunter, Gordon, Pawar, Vivek
• Granted Patent: US 7,648,735 B2
• Time in Patent Office: Days
• US Class Current: 623/23.510
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2/32 for the hip
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/44 for the spine, e.g. vertebrae, spinal discs
• CPC Class Codes: A61F 2002/2835 Bone graft implants for filling a bony defect or an endoprosthesis cavity, e.g. by synthetic material or biological material
• CPC Class Codes: A61F 2002/30261 parallelepipedal
• CPC Class Codes: A61F 2002/3092 having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30967 Diffusion bonding
• CPC Class Codes: A61F 2002/30968 Sintering
• CPC Class Codes: A61F 2002/30971 Laminates, i.e. layered products
• CPC Class Codes: A61F 2230/0082 parallelepipedal
• CPC Class Codes: A61F 2310/00011 Metals or alloys
• CPC Class Codes: A61F 2310/00089 Zirconium or Zr-based alloys
• CPC Class Codes: A61F 2310/00161 Carbon; Graphite
• CPC Class Codes: A61F 2310/00173 Graphite
• CPC Class Codes: A61F 2310/00179 Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00634 Coating made of zirconium oxide or hydroxides
• CPC Class Codes: A61L 27/306 Other specific inorganic materials not covered by A61L27/303 - A61L27/32
• CPC Class Codes: A61L 27/56 : Porous materials, e.g. foams or sponges
• CPC Class Codes: B32B 15/04 : comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: C23C 4/00 : Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge build-up welding B23K, e.g. B23K5/18, B23K9/04
• CPC Class Codes: C23C 4/10 : Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/24996 : With internal element bridging layers, nonplanar interface between layers, or intermediate layer of commingled adjacent foam layers
• CPC Class Codes: Y10T 428/24997 : Of metal-containing material
• CPC Class Codes: Y10T 428/249975 : Void shape specified [e.g., crushed, flat, round, etc.]
• CPC Class Codes: Y10T 428/24999 : Inorganic
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

A composition, a medical implant constructed from the composition, and a method of making the composition are described. The composition is a composite material, comprising a porous, reticulated, open cell network having at least part of its surface coated with blue-black or black oxidized zirconium.

Claims

1-8. -8. (canceled)

9. A method of making a composite material comprising the steps of:

providing a material having a reticulated open cell structure,

depositing a layer of zirconium or zirconium alloy onto said substrate; and

,

oxidizing said layer to blue-black or black oxidized zirconium.

10. The method of claim 9 wherein said step of depositing comprises chemical vapor deposition or physical vapor deposition or both.

11. The method of claim 9 wherein said step of oxidizing comprises oxidizing using air, steam, or water oxidation or any combination thereof.

12. The method of claim 9 wherein said step of oxidizing comprises oxidizing in a furnace having an oxygen-containing atmosphere.

13. A method of making a composite material comprising the steps of:

providing a material having a reticulated open cell structure,

physically constructing a layer of zirconium or zirconium alloy onto said substrate, and

oxidizing said layer to blue-black or black oxidized zirconium.

14. The method of claim 13 wherein said step of physical constructing comprises direct casting.

15. The method of claim 13 wherein said step of physical constructing comprises building a diffusion-bonded layer.

16-21. -21. (canceled)