Joint Replacement or Joint Resurfacing Devices, Systems and Methods

• US 20150359638A1
• Filed: 06/12/2015
• Published: 12/17/2015
• Est. Priority Date: 06/13/2014
• Status: Active Grant

• Current Assignee: Acuitive Technologies, Inc., Penn State Research Foundation
• Original Assignee: Acuitive Technologies, Inc.
• Inventors: Khowaylo, Alex, Malayter, James, McCarthy, Michael P., Washburn, David
• Granted Patent: US 9,713,655 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A61F 2002/30107 using materials or accessories for preventing galvanic or electrolytic corrosion
• CPC Class Codes: A61L 2400/18 Modification of implant surfaces in order to improve biocompatibility, cell growth, fixation of biomolecules, e.g. plasma treatment
• CPC Class Codes: A61L 2430/02 for reconstruction of bones; weight-bearing implants
• CPC Class Codes: A61L 2430/24 for joint reconstruction
• CPC Class Codes: A61L 27/045 Cobalt or cobalt alloys
• CPC Class Codes: A61L 27/06 Titanium or titanium alloys
• 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

Joint resurfacing and/or replacement devices, systems and methods that include thin film ternary ceramic coatings that are effective to provide reliable articulation and bearing surfaces and protection of both articular and modular junction surfaces from the potential for corrosion, wear, and fretting, and reduce the potential for release of metal ions from the joint systems. Isoelasticity is provided according to the particular joint resurfacing/replacement devices, systems and methods based on parameters that include material of construction, porosity and coating system. The thin film ternary ceramic coatings may be functionalized to enhance hydrophilicity and may be employed in any anatomical articulating joint region. Titanium alloy composite structures are provided that include an ultra-porous structured titanium alloy bone fixation surface and an opposed solid articular surface and a thin film ternary ceramic coating applied to one or both opposed surfaces.

Claims

1. An orthopedic device, comprising:

a first element fabricated at least in part from a titanium alloy and defining (i) a porous or ultraporous fixation region, and (ii) an engagement surface;

a thin film ternary ceramic coating applied with respect to the engagement surface at a thickness of 20 microns or less;

wherein the engagement surface is configured and dimensioned for articular movement relative to a second element; and

wherein the first element exhibits a modulus that closely matches the modulus of host bone to which it is adapted to be mounted.

2. The device of claim 1, wherein the porous or ultraporous fixation region exhibits uniform porosity, variable porosity or a combination thereof.

3. The device of claim 1, wherein the modulus of the first element closely matches the modulus of host bone based at least in part on (i) fabrication from titanium alloy, (ii) selection of desired porosity properties in the porous or ultraporous fixation region, and (iii) application of the thin film ceramic coating.

4. The device of claim 3, wherein porosity properties in the porous or ultraporous fixation region are selected and controlled based on additive manufacturing techniques.

5. The device of claim 1, wherein the porous or ultraporous fixation region includes a thin film ternary ceramic coating.

6. The device of claim 1, wherein the thin film ternary ceramic coating is selected from the group consisting of titanium aluminum nitride (TiAlN), titanium carbon nitride (TiCN), titanium niobium nitride (TiNbN), titanium silicon nitride (TiSiN), titanium zirconium nitride (TiZrN), titanium chromium nitride (TiCrN), and combinations thereof.

7. The device of claim 1, wherein the thin film ternary ceramic coating is functionalized to provide at least one of enhanced hydrophilicity, improved lubricity, improved wear properties and enhanced osteoblast proliferation.

8. The device of claim 1, wherein the first element is configured and dimensioned for use in a joint replacement or joint resurfacing application.

9. The device of claim 1, wherein the first element is configured and dimensioned for use as at least one component in a hip implant, a knee implant, an ankle implant, a shoulder implant, an elbow implant, a wrist implant, or a spinal or cervical implant.

10. The device of claim 1, wherein the first element further comprises a polyethylene liner, insert or spacer.

11. The device of claim 1, further comprising one or more intermediate coating layers positioned between the engagement surface of the first element and the thin film ternary ceramic coating.

12. The device of claim 1, wherein the thin film ternary ceramic coating is effective to prevent metal ion release from the first element.

13. The device of claim 1, wherein the thin film ternary ceramic coating is effective to provide the first element with protection against wear, fretting, and galvanic and crevice corrosion.

14. The device of claim 1, wherein the second element is selected from the group consisting of a metallic implant element, a polymeric implant element, bone, cartilage and soft tissue.

15. An orthopedic system, comprising:

a first element fabricated at least in part from a titanium alloy and defining (i) a porous or ultraporous fixation region, and (ii) a first engagement surface;

a thin film ternary ceramic coating applied with respect to the first engagement surface at a thickness of 20 microns or less;

a second element defining a second engagement surface;

wherein the first engagement surface and the second engagement surface are in physical contact with each other and are configured and dimensioned for articular movement relative to each other; and

wherein the modulus of the first element closely matches the modulus of host bone to which it is adapted to be mounted.

16. The orthopedic system of claim 15, further comprising a coating applied to the second engagement surface.

17. The orthopedic system of claim 15, wherein the coating applied to the second engagement surface is a thin film ternary ceramic coating and wherein the coating applied to the second engagement surface exhibits a different hardness as compared to the thin film ternary ceramic coating applied to the first engagement surface.

18. The orthopedic system of claim 15, wherein the coating applied to the second engagement surface is selected from the group consisting of a metal nitride, a metal carbide, a metal oxide, diamond-like carbon (DLC) and combinations thereof.

19. The orthopedic system of claim 15, wherein the first element and the second element are configured and dimensioned for use in a joint replacement or joint resurfacing application.

20. The orthopedic system of claim 15, wherein the first element and the second element are configured and dimensioned for use in a hip implant, a knee implant, an ankle implant, a shoulder implant, an elbow implant, a wrist implant, or a spinal or cervical implant.

21. A modular junction associated with an orthopedic device, comprising:

a first metallic element defining a stem portion;

a second metallic element defining a tapered bore configured and dimensioned to receive at least a portion of the stem portion;

a thin film ternary ceramic coating applied with respect to at least one of the stem portion and the tapered bore at a thickness of 20 microns or less;

wherein the thin film ternary ceramic coating is effective to prevent wear, fretting, metal ion release, and galvanic and crevice corrosion at the coated surface.

22. A joint replacement or resurfacing system, comprising:

an element fabricated from a metallic material and defining an engagement surface;

a thin film ternary ceramic coating applied to the engagement surface at a thickness of 20 microns or less;

wherein the engagement surface is configured and dimensioned to be placed in physical contact with a second element for articular movement relative thereto.

23. The system according to claim 22, wherein the metallic material is selected from the group consisting of cobalt chrome and a cobalt chrome alloy.