DYNAMIC POROUS COATING FOR ORTHOPEDIC IMPLANT

• US 20130218288A1
• Filed: 03/15/2013
• Published: 08/22/2013
• Est. Priority Date: 02/09/2012
• Status: Active Grant

• Current Assignee: Arthrex Incorporated
• Original Assignee: MX Orthopedics Corp
• Inventors: Fonte, Matthew, Palmer, Matthew
• Granted Patent: US 9,155,819 B2
• Time in Patent Office: Days
• US Class Current: 623/23.5
• 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 2/30907 Nets or sleeves applied to surface of prostheses or in cement
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2/34 Acetabular cups
• CPC Class Codes: A61F 2/3662 Femoral shafts
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2002/30092 using shape memory or superelastic materials, e.g. nitinol
• CPC Class Codes: A61F 2002/3028 polyhedral different from parallelepipedal and pyramidal
• CPC Class Codes: A61F 2002/30579 with mechanically expandable devices, e.g. fixation devices
• CPC Class Codes: A61F 2002/3084 Nanostructures
• CPC Class Codes: A61F 2002/30911 having a honeycomb structure
• CPC Class Codes: A61F 2002/30912 made of expanded metal, e.g. diamond mesh or metal nets having lozenge-shaped apertures
• CPC Class Codes: A61F 2002/30914 Details of the mesh structure, e.g. disposition of the woven warp and weft wires
• CPC Class Codes: A61F 2002/30915 made of a stack of bonded perforated sheets, grids or wire meshes
• CPC Class Codes: A61F 2002/30919 Sleeves
• CPC Class Codes: A61F 2002/3092 having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30929 having at least two superposed coatings
• CPC Class Codes: A61L 2400/16 Materials with shape-memory or superelastic properties
• CPC Class Codes: A61L 2430/02 for reconstruction of bones; weight-bearing implants
• 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

Abstract

A dynamic porous coating for an orthopedic implant, wherein the dynamic porous coating is adapted to apply an expansive force against adjacent bone so as to fill gaps between the dynamic porous coating and adjacent bone and to create an interference fit between the orthopedic implant and the adjacent bone.

Claims

1. A dynamic porous coating for an orthopedic implant, wherein the dynamic porous coating is adapted to apply an expansive force against adjacent bone so as to fill gaps between the dynamic porous coating and adjacent bone and to create an interference fit between the orthopedic implant and the adjacent bone.

2. A dynamic porous coating according to claim 1 wherein the dynamic porous coating comprises shape memory material.

3. A dynamic porous coating according to claim 2 wherein the expansive force is created by the superelasticity of the shape memory material.

4. A dynamic porous coating according to claim 2 wherein the expansive force is created by the shape memory effect of the shape memory material.

5. A dynamic porous coating according to claim 1 wherein the dynamic porous coating is elastic.

6. A dynamic porous coating according to claim 5 wherein the dynamic porous coating comprises a shape memory material, and further wherein the expansive force is created by the superelasticity of the shape memory material.

7. A dynamic porous coating according to claim 1 wherein the dynamic porous coating comprises spacer fabric.

8. A dynamic porous coating according to claim 7 wherein the spacer fabric comprises filaments formed out of shape memory material.

9. A dynamic porous coating according to claim 8 wherein the expansive force is created by the superelasticity of the shape memory material.

10. A dynamic porous coating according to claim 8 wherein the expansive force is created by the shape memory effect of the shape memory material.

11. A dynamic porous coating according to claim 1 wherein the expansive force applied by the porous coating causes bone remodeling.

12. A dynamic porous coating according to claim 1 wherein the dynamic porous coating is formed by coating foam with a shape memory material, removing the foam and then attaching the resulting structure to the orthopedic implant.

13. A dynamic porous coating according to claim 1 wherein the dynamic porous coating comprises wire formed out of a shape memory material and which is knit, woven or braided.

14. A dynamic porous coating according to claim 1 wherein the dynamic porous coating comprises a honeycomb or truss-based structure formed out of shape memory material.

15. A dynamic porous coating according to claim 1 wherein the dynamic porous coating comprises sintered beads formed out of shape memory material.

16. A dynamic porous coating according to claim 1 wherein the dynamic porous coating comprises multiple layers laminated to one another, and further wherein at least one of the multiple layers comprises shape memory material.

67. A dynamic porous coating according to claim 1 wherein the spacer fabric has approximately 3-99% strain recovery.

71. A dynamic porous coating according to claim 1 wherein the dynamic porous coating is capable of expanding at least 0.025 inch.

17. An orthopedic implant comprising a substrate and a dynamic porous coating secured to the substrate, wherein the dynamic porous coating is adapted to apply an expansive force against adjacent bone so as to fill gaps between the dynamic porous coating and adjacent bone and to create an interference fit between the orthopedic implant and the adjacent bone.

18. An orthopedic implant according to claim 17 wherein the dynamic porous coating comprises shape memory material.

19. An orthopedic implant according to claim 18 wherein the expansive force is created by the superelasticity of the shape memory material.

20. An orthopedic implant according to claim 18 wherein the expansive force is created by the shape memory effect of the shape memory material.

21. An orthopedic implant according to claim 17 wherein the dynamic porous coating is elastic.

22. An orthopedic implant according to claim 21 wherein the dynamic porous coating comprises a shape memory material, and further wherein the expansive force is created by the superelasticity of the shape memory material.

23. An orthopedic implant according to claim 17 wherein the dynamic porous coating comprises spacer fabric.

24. An orthopedic implant according to claim 23 wherein the spacer fabric comprises filaments formed out of shape memory material.

25. An orthopedic implant according to claim 24 wherein the expansive force is created by the superelasticity of the shape memory material.

26. An orthopedic implant according to claim 24 wherein the expansive force is created by the shape memory effect of the shape memory material.

27. An orthopedic implant according to claim 17 wherein the expansive force applied by the porous coating causes bone remodeling.

28. An orthopedic implant according to claim 17 wherein the dynamic porous coating is formed by coating foam with a shape memory material, removing the foam and then attaching the resulting structure to the orthopedic implant.

29. An orthopedic implant according to claim 17 wherein the dynamic porous coating comprises wire formed out of a shape memory material and which is knit, woven or braided.

30. An orthopedic implant according to claim 17 wherein the dynamic porous coating comprises a honeycomb or truss-based structure formed out of shape memory material.

31. An orthopedic implant according to claim 17 wherein the dynamic porous coating comprises sintered beads formed out of shape memory material.

32. An orthopedic implant according to claim 17 wherein the dynamic porous coating comprises multiple layers laminated to one another, and further wherein at least one of the multiple layers comprises shape memory material.

62. An orthopedic implant according to claim 17 wherein the orthopedic implant comprises one from the group consisting of a femoral hip stem implant, an acetabular hip implant, a femoral condyle knee implant, a tibial tray knee implant, a shoulder implant, and an elbow implant.

66. An orthopedic implant according to claim 17 wherein the orthopedic implant comprises one from the group consisting of a spinal implant, an extremity implant, a dental implant, a cranial implant, and a maxillofacial implant.

68. An orthopedic implant according to claim 17 wherein the spacer fabric has approximately 3-99% strain recovery.

72. An orthopedic implant according to claim 17 wherein the dynamic porous coating is capable of expanding at least 0.025 inch.

33. A method for providing therapy to a patient, the method comprising:

providing an orthopedic implant comprising a substrate and a dynamic porous coating secured to the substrate, wherein the dynamic porous coating is adapted to apply an expansive force against adjacent bone so as to fill gaps between the dynamic porous coating and adjacent bone and to create an interference fit between the orthopedic implant and the adjacent bone;

inserting the orthopedic implant into a bone cavity in the patient so that the dynamic porous coating applies an outward force against adjacent bone so as to fill gaps between the dynamic porous coating and adjacent bone and to create an interference fit between the orthopedic implant and the adjacent bone.

34. A method according to claim 33 wherein the dynamic porous coating comprises shape memory material.

35. A method according to claim 34 wherein the expansive force is created by the superelasticity of the shape memory material.

36. A method according to claim 34 wherein the expansive force is created by the shape memory effect of the shape memory material.

37. A method according to claim 33 wherein the dynamic porous coating is elastic.

38. A method according to claim 37 wherein the dynamic porous coating comprises a shape memory material, and further wherein the expansive force is created by the superelasticity of the shape memory material.

39. An orthopedic implant according to claim 33 wherein the dynamic porous coating comprises spacer fabric.

40. A method according to claim 39 wherein the spacer fabric comprises filaments formed out of shape memory material.

41. A method according to claim 40 wherein the expansive force is created by the superelasticity of the shape memory material.

42. A method according to claim 40 wherein the expansive force is created by the shape memory effect of the shape memory material.

43. A method according to claim 33 wherein the expansive force applied by the porous coating causes bone remodeling.

44. A method according to claim 33 wherein the dynamic porous coating is formed by coating foam with a shape memory material, removing the foam and then attaching the resulting structure to the orthopedic implant.

45. A method according to claim 33 wherein the dynamic porous coating comprises wire formed out of a shape memory material and which is knit, woven or braided.

46. A method according to claim 33 wherein the dynamic porous coating comprises a honeycomb or truss-based structure formed out of shape memory material.

47. A method according to claim 33 wherein the dynamic porous coating comprises sintered beads formed out of shape memory material.

48. A method according to claim 33 wherein the dynamic porous coating comprises multiple layers laminated to one another, and further wherein at least one of the multiple layers comprises shape memory material.

63. A method according to claim 33 wherein the orthopedic implant is inserted into the patient during revision surgery.

49. A dynamic porous coating for an orthopedic implant, the dynamic porous coating comprising:

a spacer fabric comprising;

an inner layer formed by fibers;

an outer layer formed by fibers;

the outer layer being spaced from the inner layer; and

the outer layer being connected to the inner layer by a plurality of connecting fibers extending between the inner layer and the outer layer, such that the outer layer is capable of applying an outward force against adjacent bone.

50. A dynamic porous coating according to claim 49 wherein the dynamic porous coating is elastic.

51. A dynamic porous coating according to claim 50 wherein the connecting fibers are formed from a superelastic material, and further wherein the outward force is generated by superelasticity.

52. A dynamic porous coating according to claim 50 wherein the connecting fibers are formed from a superelastic material, and further wherein the outward force is generated by the shape memory effect.

53. A dynamic porous coating according to claim 50 wherein the space between the inner layer and the outer layer is characterized by a plurality of channels formed by the connecting fibers.

54. A dynamic porous coating according to claim 50 wherein the spacer fabric has a thickness of from about 0.25 mm to about 10 mm.

55. A dynamic porous coating according to claim 50 wherein the spacer fabric is approximately 50-98% porous.

56. A dynamic porous coating according to claim 50 wherein the spacer fabric comprises a bioresorbable material.

57. A dynamic porous coating according to claim 50 wherein the fibers of the inner layer and the outer layer, and the connecting fibers, comprise at least two different types of fibers.

58. A dynamic porous coating according to claim 50 wherein the spacer fabric is configured to have a modulus of elasticity of approximately 0.100-20 GPa.

59. A dynamic porous coating according to claim 50 wherein the spacer fabric has approximately 3-99% strain recovery.

60. A dynamic porous coating according to claim 50 wherein the spacer fabric is collapsed and maintained in a collapsed condition using a resorbable calcium phosphate bone putty or cement which, upon resorbing, allows the spacer fabric to resume its previous state.

61. A dynamic porous coating according to claim 50 wherein the spacer fabric is secured to an orthopedic implant by one of brazing with silver, sintering, and diffusion bonding.

64. A dynamic porous coating according to claim 49 wherein the inner layer comprises pores, the outer layer comprises pores, and the size of the pores of the inner layer differs from the size of the pores of the outer layer.

65. A dynamic porous coating according to claim 49 wherein at least some of the fibers are coated.

69. A dynamic porous coating according to claim 49 wherein the spacer fabric has a modulus of elasticity which varies according to the degree of compression imposed on the spacer fabric.

70. A dynamic porous coating according to claim 69 wherein the spacer fabric has a relatively low modulus of elasticity when the spacer fabric has relatively little compression imposed on it, and further wherein the spacer fabric has a relatively high modulus of elasticity when the spacer fabric has a large compression imposed on it.

73. A dynamic porous coating according to claim 49 wherein the dynamic porous coating is capable of expanding at least 0.025 inch.