Surgical implant having multiple layers of sintered porous coating and method
First Claim
1. A prosthetic implant comprising the combination of a metallic substrate and a porous metallic layer on at least a portion of said substrate, said porous metallic layer being of different composition from said metallic substrate, the porous layer being joined to said substrate through an intermediate, non- porous layer, said intermediate layer having substantially the same composition as the porous layer.
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Accused Products
Abstract
A surgical prosthetic device for implant in a patient and method for making said device, the device comprising a composite structure having a solid metal substrate and a porous coating with multiple sintered layers. The porous coating has an external layer to accept bone ingrowth. An intermediate layer bonds the external porous layer to the substrate. The layers are applied in a process of multiple sintering, whereby each successive layer is individually sintered to the substrate or to the proceeding layer, as applicable. This process provides a porous area having increased strength of attachment between the substrate and the external porous layer. An acid etch solution promotes adhesion between the substrate and the intermediate layer thus increasing the consistency of the process. The initial sintering is held at elevated temperature for less time than the sintering of the external layer. At the end of each sintering step, the prosthesis is quick cooled using an inert gas, preferably helium.
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Citations
20 Claims
- 1. A prosthetic implant comprising the combination of a metallic substrate and a porous metallic layer on at least a portion of said substrate, said porous metallic layer being of different composition from said metallic substrate, the porous layer being joined to said substrate through an intermediate, non- porous layer, said intermediate layer having substantially the same composition as the porous layer.
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3. A method of applying a porous coating to a selected portion of surface of a prosthetic implant substrate comprised of a first metallic substance, the method comprising the successive steps of:
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cleaning at leas the selected portion of the surface of the substrate; applying a slurry containing a powder comprised of a second metallic substance to said selected portion; drying said slurry to leave at least said powder as a residue on said selected portion; sintering said powder on said substrate to form an intermediate metallic layer; applying a mixture comprised of a particulate and a filler material for forming pores, said particulate being comprised substantially of said second metallic substance, and sintering said mixture on said intermediate layer. - View Dependent Claims (4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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Specification