Hard tissue prosthesis including porous thin metal sheets

• US 5,496,372 A
• Filed: 12/01/1993
• Issued: 03/05/1996
• Est. Priority Date: 04/17/1992
• Status: Expired due to Term

• Current Assignee: Kyocera Corporation
• Original Assignee: Kyocera Corporation
• Inventors: Ishida, Noriyuki, Hamamoto, Shoichi, Nishio, Yoichi, Amino, Hirokazu, Tamura, Yasunori, Ichimiya, Masaru
• Primary Examiner(s): Prebilic, Paul B.
• Application Number:
  US08/159,654
• Time in Patent Office: 825 Days
• Field of Search: 623/16, 623/18, 623/20, 623/22, 623/23, 606/70, 606/69
• US Class Current: 623/23.54
• 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: A61C 8/0013 with a surface layer, coating
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/30 Joints
• CPC Class Codes: A61F 2/30734 Modular inserts, sleeves or augments, e.g. placed on proximal part of stem for fixation purposes or wedges for bridging a bone defect
• 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 2/32 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 2/3601 for replacing only the epiphyseal or metaphyseal parts of the femur, e.g. endoprosthetic femoral heads or necks directly fixed to the natural femur by internal fixation devices non-prosthetic internal fixation devices for the femoral head or neck A61B17/74
• CPC Class Codes: A61F 2/367 Proximal or metaphyseal parts of shafts trochanteric devices connected to said proximal parts A61F2/30739
• CPC Class Codes: A61F 2/44 for the spine, e.g. vertebrae, spinal discs
• CPC Class Codes: A61F 2002/30112 Rounded shapes, e.g. with rounded corners
• CPC Class Codes: A61F 2002/30158 trapezoidal
• CPC Class Codes: A61F 2002/30261 parallelepipedal
• CPC Class Codes: A61F 2002/30433 using additional screws, bolts, dowels, rivets or washers e.g. connecting screws
• CPC Class Codes: A61F 2002/30785 parallel
• CPC Class Codes: A61F 2002/30911 : having a honeycomb structure
• CPC Class Codes: A61F 2002/30915 : made of a stack of bonded perforated sheets, grids or wire meshes
• 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: A61F 2002/30971 : Laminates, i.e. layered products
• CPC Class Codes: A61F 2002/3605 : made of two or more concentric caps fitted onto one another
• CPC Class Codes: A61F 2220/0041 : using additional screws, bolts, dowels or rivets, e.g. connecting screws
• CPC Class Codes: A61F 2230/0004 : Rounded shapes, e.g. with rounded corners
• CPC Class Codes: A61F 2230/0026 : trapezoidal
• CPC Class Codes: A61F 2230/0082 : parallelepipedal
• CPC Class Codes: A61F 2240/001 : Designing or manufacturing processes
• 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 2310/00796 : Coating or prosthesis-covering structure made of a phosphorus-containing compound, e.g. hydroxy(l)apatite
• CPC Class Codes: A61L 27/04 : Metals or alloys
• CPC Class Codes: A61L 27/56 : Porous materials, e.g. foams or sponges
• CPC Class Codes: Y10S 606/907 : Composed of particular material or coated
• CPC Class Codes: Y10T 29/496 : Multiperforated metal article making

Abstract

A prosthesis for the replacement of hard tissues of human bones and joints, comprising a porous lamination component of metal thin sheets, each having a plurality of through holes and a thickness of 150 μm or less, and being unharmful to the living body, the porous lamination component being formed such that the sheets are laid over one another and are then diffusion-bonded therebetween into one body by heating so that the through holes communicate with one another in the direction of the thickness thereof, and the prosthesis being entirely or partially composed of the porous lamination component. The present invention also relates to a method of making such a prosthesis. The present invention can provide prostheses which are not required to be replaced again, thereby imposing a less burden to patients.

Claims

1. A prosthesis for the replacement of hard tissues of human bones and joints comprising a porous lamination component of metal thin sheets, each having a plurality of through holes and a thickness along a first dimension of 150 μ

m or less, and being unharmful to the living body, said porous lamination component being formed such that said thin sheets are laid over one another and then diffusion-bonded therebetween into one body by heating so that said through holes communicate with one another in the direction of the first dimension, wherein a single hole formed in at least one of a pair of said thin sheets being vertically adjacent to each other communicates with a plurality of holes formed in the other of the pair in the plan view direction of said thin sheets;

said single hole is larger than said plurality of holes of said pair of said thin sheets such that said single hole encloses said plurality of holes of said pair of said thin sheets.

2. The prosthesis of claim 1, wherein the prosthesis consists of said porous lamination component.

3. The prosthesis of claim 1, wherein the prosthesis defines a base having a surface and wherein the prosthesis is partially composed of said porous lamination component at a desired portion of the surface of the prosthesis base.

4. The prosthesis of claim 1, wherein said porous lamination component is covered at a desired surface portion thereof by a covering metal material being highly bio-compatible and corrosion-resistive in the living tissues or highly bonding-affinitive to other prostheses.

5. The prosthesis of claim 1, wherein the effective diameter of said through holes is in the range of 100 to 400 μ

m.

6. The prosthesis of claim 1, wherein the volume porosity of said porous lamination component is in the range of 45 to 85%.