Textured surface having undercut micro recesses in a surface

• US 20060129161A1
• Filed: 02/01/2006
• Published: 06/15/2006
• Est. Priority Date: 01/25/2001
• Status: Active Grant

• Current Assignee: Tecomet, Inc.
• Original Assignee: Tecomet, Inc.
• Inventors: Amrich, Mark, Rolfe, Jonathan L., Buturlia, Joseph, Lynch, Robert F.
• Granted Patent: US 7,850,862 B2
• Time in Patent Office: Days
• US Class Current: 606/85
• CPC Class Codes: A61B 17/8085 with pliable or malleable elements or having a mesh-like structure, e.g. small strips A61B17/8071, A61B17/8076 take precedence
• CPC Class Codes: A61C 2008/0046 Textured surface, e.g. roughness, microstructure A61C8/0013 takes precedence
• 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 2/2803 for mandibular reconstruction temporo-mandibular joints A61F2/3099; bone plates for the jaw A61B17/8071
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/30771 applied in original prostheses, e.g. holes or grooves
• 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 2/3662 Femoral shafts
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/446 having a circular or elliptical cross-section substantially parallel to the axis of the spine, e.g. cylinders or frustocones
• CPC Class Codes: A61F 2002/30149 pentagonal
• CPC Class Codes: A61F 2002/30153 rectangular
• CPC Class Codes: A61F 2002/3021 frustoconical
• CPC Class Codes: A61F 2002/30217 hollow cones, e.g. tubular-like cones
• CPC Class Codes: A61F 2002/30253 ellipsoidal or ovoid
• CPC Class Codes: A61F 2002/30535 Special structural features of bone or joint prostheses not otherwise provided for
• CPC Class Codes: A61F 2002/30777 Oblong apertures
• CPC Class Codes: A61F 2002/30785 parallel
• CPC Class Codes: A61F 2002/30787 : inclined obliquely with respect to each other
• CPC Class Codes: A61F 2002/30838 : Microstructures
• CPC Class Codes: A61F 2002/30873 : Threadings machined on non-cylindrical external surfaces
• CPC Class Codes: A61F 2002/30879 : Ribs
• CPC Class Codes: A61F 2002/30883 : dovetail-shaped
• CPC Class Codes: A61F 2002/30892 : parallel
• CPC Class Codes: A61F 2002/30925 : etched
• CPC Class Codes: A61F 2002/30952 : using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/3097 : using laser
• CPC Class Codes: A61F 2002/3611 : Heads or epiphyseal parts of femur
• CPC Class Codes: A61F 2002/3625 : Necks
• CPC Class Codes: A61F 2002/3631 : with an integral complete or partial peripheral collar or bearing shoulder at its base
• CPC Class Codes: A61F 2002/365 : Connections of heads to necks
• CPC Class Codes: A61F 2230/0017 : Angular shapes
• CPC Class Codes: A61F 2230/0019 : rectangular
• CPC Class Codes: A61F 2230/0067 : conical
• CPC Class Codes: A61F 2230/0076 : ellipsoidal or ovoid
• CPC Class Codes: A61F 2250/0058 : Additional features; Implant or prostheses properties not otherwise provided for
• 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 2310/00089 : Zirconium or Zr-based alloys
• CPC Class Codes: A61F 2310/00131 : Tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00179 : Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00269 : based on metal carbides
• CPC Class Codes: A61F 2310/00329 : Glasses, e.g. bioglass
• CPC Class Codes: B23K 2103/14 : Titanium or alloys thereof
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: C23F 1/02 : Local etching

Abstract

Textured surface having micro recesses such that the outer surface overhangs the micro recesses. Embodiments of the textured surface include sharp edges for promoting bone deposition and growth within the micro recesses, protrusions of varying depth from the surface that include overhangs, and micro recesses that are at least partially defined by complex ellipsoids.

Claims

1-55. -55. (canceled)

56. A method for producing a multiplicity of undercut micro recesses in a surface of an article, the article thereby exhibiting a greater fractal area at a level below the surface than is exhibited at the surface, the method comprising:

applying a maskant layer to substantially an entirety of the surface of the article;

removing portions of the maskant layer in selected loci to expose underlying portions of the article surface in a selected pattern;

applying an etchant to the exposed underlying surface portions for a time sufficient to etch the exposed surface portions and to enable the etchant to etch beneath remaining portions of the maskant layer and produce a multiplicity of undercut recesses; and

removing the remaining maskant layer portions to provide the article surface in exposed condition with the multiplicity of recesses undercut and comprising interconnected recesses, to provide an engineered pattern of the recesses.

57. The method in accordance with claim 56, wherein the maskant comprises a material selected from a group consisting of an acrylic, an epoxy, and a polyester.

58. The method in accordance with claim 57, wherein the maskant further comprises a material selected from the group consisting of a dye and a pigment.

59. The method in accordance with claim 56, wherein the maskant layer is about 0.001-0.010 inch thick.

60. The method in accordance with claim 58 and further comprising dispersing the pigment in the maskant in a mixer, and mixing the maskant and pigment therein until a temperature rise of 15°

-20°

C. is realized by the mixture.

61. The method in accordance with claim 56, wherein applying the maskant layer to the surface of the article comprises a step selected from the group consisting of dipping, spraying, spinning, brushing, and electrostatically depositing the maskant onto the article.

62. The method in accordance with claim 56, wherein removal of the maskant is effected by laser ablation.

63. The method in accordance with claim 62, wherein the laser ablation is computer controlled.

64. The method in accordance with claim 63, wherein the pattern is formed by selectively removing the maskant by an active laser projection pattern.

65. The method in accordance with claim 56, wherein the application of etchant to exposed surface portions of the article is effected by a spray etcher.

66. The method in accordance with claim 65, wherein the spray etcher is operated at 100°

F. spray temperature and 10 lbs/in² spray pressure in a nitric-hydrofluoric acid solution for about 20 minutes.

67. The method in accordance with claim 63, wherein the controlling computer operates in conjunction with a CAD system having facility for storing patterns in digital format or transferring said data into a photo tool.

68. The method in accordance with claim 62, wherein the laser ablation is effected by a laser selected from the group consisting of a YAG laser, a CO₂ laser, and a green laser, and other laser providing a wavelength appropriate for absorption of the maskant.

69. The method in accordance with claim 56, wherein the undercut recesses are of a non-spherical configuration.

70. The method in accordance with claim 69 wherein the configuration is substantially ovoid.

71. A method for producing a multiplicity of undercut micro recesses in a surface of an article in a selected pattern which can be repeated in any selected number of surfaces, the method comprising:

applying a maskant layer to substantially an entirety of a selected surface of the article;

removing portions of the maskant layer by computer-directed laser ablation in programmed loci to expose underlying portions of the surface of the article in a programmed pattern;

applying an etchant to the exposed underlying surface portions for a time sufficient to etch the exposed surface portions and to enable the etchant to etch beneath remaining portions of the maskant layer and produce a multiplicity of undercut recesses; and

removing the remaining maskant layer portions to provide the selected surface in exposed condition with the multiplicity of undercut recesses therein.

72. The method in accordance with claim 71, wherein the undercut recesses are of a non-spherical configuration.

73. The method in accordance with claim 72, wherein the configuration is substantially ovoid.

74. A method for attaching a surgical implant to a bone, the method comprising:

providing a surgical implant having a datum surface, a multiplicity of micro recesses in the datum surface, and bone milling structure on the datum surface;

pressing the datum surface against a surface of the bone;

and

urging the implant along the bone surface to mill particulate bone matter from the bone;

wherein the recesses are adapted to receive and retain the particulate bone matter which stimulates ingrowth of the bone.

75. The method in accordance with claim 74, wherein the undercut recesses are of a non-spherical configuration.

76. The method in accordance with claim 75, where in the configuration is substantially ovoid.