Implant prosthesis and method for producing same

• US 5,397,362 A
• Filed: 09/27/1993
• Issued: 03/14/1995
• Est. Priority Date: 06/30/1989
• Status: Expired due to Term

• Current Assignee: Kyocera Corporation
• Original Assignee: Kyocera Corporation
• Inventors: Noda, Iwao
• Primary Examiner(s): Shay, Randy C.
• Application Number:
  US08/127,422
• Time in Patent Office: 533 Days
• Field of Search: 623/16, 623/18, 433/201.1
• US Class Current: 623/23.56
• CPC Class Codes: A61F 2310/00796 Coating or prosthesis-covering structure made of a phosphorus-containing compound, e.g. hydroxy(l)apatite
• CPC Class Codes: A61L 27/10 Ceramics or glasses
• CPC Class Codes: A61L 27/30 Inorganic materials
• CPC Class Codes: A61L 27/32 Phosphorus-containing materials, e.g. apatite
• CPC Class Codes: B24C 1/00 Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
• CPC Class Codes: C04B 2111/00836 for medical or dental applications
• CPC Class Codes: C04B 35/00 Shaped ceramic products characterised by their composition porous ceramic products C04B38/00; ceramic articles characterised by particular shape, see the relevant classes, e.g. linings for casting ladles, tundishes, cups or the like B22D41/02; ceramic substrates for microelectronic semi-conductors H01L23/15; Ceramics compositions containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides other than as macroscopic reinforcing agents C22C; shaping of ceramics B28B; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products chemical preparation of powders of inorganic compounds C01; infiltration of sintered ceramic preforms with molten metal C04B41/51
• CPC Class Codes: C04B 41/0072 Heat treatment
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4527 Plasma spraying deposition from the gas phase using plasma C04B41/4533
• CPC Class Codes: C04B 41/5022 with vitreous materials composition of vitreous glazes and enamels C03C; ceramic pigments C09C1/0009
• CPC Class Codes: C04B 41/5048 Phosphates
• CPC Class Codes: C04B 41/52 Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
• CPC Class Codes: C04B 41/53 involving the removal of at least part of the materials of the treated article, e.g. etching, drying of hardened concrete C04B41/0036 - C04B41/0054 take precedence
• CPC Class Codes: C04B 41/89 for obtaining at least two superposed coatings having different compositions
• CPC Class Codes: C23C 4/02 Pretreatment of the material to be coated, e.g. for coating on selected surface areas
• CPC Class Codes: C23C 4/10 Oxides, borides, carbides, nitrides or silicides; Mixtures thereof

Abstract

An implant prosthesis comprising implant substrate of ceramic material, a thin glass layer coated over the adhering interface of the substrate relative at least to a bone, and a thermally sprayed layer of calcium phosphate based material formed over the glass layer.

The implant provides excellent adhesion of the thermally sprayed layer of calcium phosphate based material to the substrate, with ensuring advantages of stabilized implantation in a living body in that the thin glass layer between the substrate and the calcium phosphate based material removes fear of the sprayed material coming off and/or falling off the substrate or possibility of bringing about reduced strength of the substrate.

Claims

1. An implant prosthesis produced by the steps of:

(a) providing a substrate of ceramic material;

(b) coating the substrate with a thin glass layer, the thin glass layer defining a surface remote from the substrate;

(c) roughening the surface of the thin glass layer remote from the substrate;

(d) thermally spraying a layer of calcium phosphate-based material on the roughened surface of said glass layer; and

(e) firing said layer of calcium phosphate based material at a temperature in the range of 600°

to 1100°

C.

2. An implant prosthesis according to claim 1, wherein said ceramic material is selected from the group consisting of monocrystalline alumina ceramics, polycrystalline alumina ceramics, zirconium dioxide ceramic, and said calcium phosphate-based material is hydroxyapatite or tricalcium phosphate.

3. An implant prosthesis according to claim 1, wherein the step of roughening the surface of the glass layer comprises the step of sandblasting the surface of the glass layer.

4. An implant prosthesis according to claim 3, further including, prior to step (d), the step of firing said glass layer at a temperature in the range of 900°

to 1300°

C.

5. An implant prosthesis according to claim 4, wherein said glass layer obtained in step (b) has a thermal expansion coefficient of from 4.0×

10^-6 /°

C. to 9.0×

10^-6 /°

C. and said ceramic material is alumina.

6. An implant prosthesis according to claim 1, further including, prior to step (d), the step of firing said glass layer at a temperature in the range of 900°

to 130°

C.

7. An implant prosthesis according to claim 1, wherein said glass layer obtained in step (b) has a thermal expansion coefficient of from 3.0×

10^-6 /°

C. to 12.0×

10^-6/°

C.

8. An implant prosthesis according to claim 1, wherein said glass layer is 0,001-2 mm in thickness and said thermally sprayed layer is 0,005-1 mm in thickness.