Method for forming biocompatible components using an isostatic press

• US 5,505,984 A
• Filed: 01/21/1993
• Issued: 04/09/1996
• Est. Priority Date: 01/21/1993
• Status: Expired due to Term

• Current Assignee: Hercules Incorporated (Ashland Global Holdings, Inc.), Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Hercules Incorporated (Ashland Global Holdings, Inc.), Biomet Incorporated (Zimmer Biomet Holdings, Inc.)
• Inventors: Higgins, Joel C., England, Garry L.
• Primary Examiner(s): LUSIGNAN, MICHAEL R
• Application Number:
  US08/006,740
• Time in Patent Office: 1,174 Days
• Field of Search: 427/2, 427/331, 427/370, 427/455, 427/456, 427/2.24, 427/2.26, 427/2.27, 623/901, 419/49
• US Class Current: 427/2.24
• 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 2/3094 Designing or manufacturing processes
• 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 2/38 for elbows or knees
• CPC Class Codes: A61F 2002/30065 thermoplastic, i.e. softening or fusing when heated, and hardening and becoming rigid again when cooled
• CPC Class Codes: A61F 2210/0071 thermoplastic
• CPC Class Codes: A61F 2310/00407 Coating made of titanium or of Ti-based alloys
• CPC Class Codes: A61F 2310/00413 Coating made of cobalt or of Co-based alloys
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/115 by spraying molten metal, i.e. spray sintering, spray casting
• CPC Class Codes: B22F 3/1216 Container composition
• CPC Class Codes: B22F 3/15 Hot isostatic pressing
• CPC Class Codes: B22F 7/002 of porous nature
• CPC Class Codes: B29C 2791/001 Shaping in several steps
• CPC Class Codes: B29C 43/006 Pressing and sintering powders, granules or fibres
• CPC Class Codes: B29C 43/10 Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
• CPC Class Codes: B29C 43/12 using bags surrounding the moulding material or using membranes contacting the moulding material
• CPC Class Codes: B29C 43/14 in several steps
• CPC Class Codes: B29K 2023/0683 : UHMWPE, i.e. ultra high molecular weight polyethylene
• CPC Class Codes: B29K 2101/12 : Thermoplastic materials
• CPC Class Codes: B29K 2105/04 : cellular or porous
• CPC Class Codes: B29K 2105/12 : of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2105/251 : Particles, powder or granules expandable particles B29K2105/046
• CPC Class Codes: B29K 2995/0056 : Biocompatible, e.g. biopolymers or bioelastomers
• CPC Class Codes: B29K 2995/0089 : Impact strength or toughness
• CPC Class Codes: B29L 2031/7532 : Artificial members, protheses
• CPC Class Codes: B30B 11/001 : using a flexible element, e.g. diaphragm, urged by fluid pressure; Isostatic presses
• CPC Class Codes: C01B 33/02 : Silicon forming single crystals or homogeneous polycrystalline material with defined structure C30B
• CPC Class Codes: C22C 33/00 : Making ferrous alloys
• CPC Class Codes: C23C 4/18 : After-treatment
• CPC Class Codes: Y10S 623/901 : Method of manufacturing prosthetic device
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31855 : Of addition polymer from unsaturated monomers

Abstract

A method for forming a biocompatible component from a biocompatible thermoplastic material and a biocompatible fibrous material using an isostatic press. The method includes the steps of placing the biocompatible thermoplastic material and the biocompatible fibrous material in a flexible container. The flexible container is then heated under pressure so as to cause the biocompatible thermoplastic material to encapsulate the biocompatible fibrous material. The flexible container is then cooled so as to form the biocompatible component.

Claims

1. A method for applying a porous coating having enhanced adhesion to a biocompatible component formed from a fibrous material, said method comprising the steps of:

providing said biocompatible component;

plasma spraying a porous coating on at least a portion of said biocompatible component; and

subjecting said biocompatible component and said porous coating to heat and pressure thereby enhancing the adhesion of said porous coating to said biocompatible component.

2. The method according to claim 1, further comprising the step of placing said biocompatible component with said porous coating in a flexible container prior to subjecting said biocompatible component and said porous coating to heat and pressure.

3. The method according to claim 2, wherein said step of placing said biocompatible component with said porous coating in a flexible container includes the steps of:

placing said biocompatible component in a flexible container formed from silicon; and

heating said flexible container under pressure thereby enhancing the adhesion of said porous coating to said biocompatible component.

4. The method according to claim 1, further comprising the step of placing said biocompatible component with said porous coating within a container including beads prior to subjecting said biocompatible component and said porous coating to heat and pressure.

5. The method according to claim 1 wherein the step of subjecting said biocompatible component and said porous coating to heat and pressure comprises subjecting said biocompatible component and said porous coating to a pressure of greater than about 5000 psi.

6. The method according to claim 1 wherein the step of subjecting said biocompatible component and said porous coating to heat and pressure comprises subjecting said biocompatible component and said porous coating to a temperature of from about 400°

F. to about 440°

F.

7. A method for applying a porous coating having enhanced adhesion to a biocompatible component, said method comprising the steps of:

providing a biocompatible component formed from a fibrous material;

forming a porous coating on at least a portion of said biocompatible component; and

subjecting said biocompatible component and said porous coating to heat and pressure thereby enhancing the adhesion of said porous coating to said biocompatible component;

wherein said step of forming a porous coating on said biocompatible component includes the step of applying a plasma spray to said biocompatible component.

8. The method according to claim 7 further comprising the step of placing said biocompatible component with said porous coating within a container including beads prior to subjecting said biocompatible component and said porous coating to heat and pressure.

9. The method according to claim 7 wherein the step of subjecting said biocompatible component and said porous coating to heat and pressure comprises subjecting said biocompatible component and said porous coating to a pressure of greater than about 5000 psi.

10. The method according to claim 7 wherein the step of subjecting said biocompatible component and said porous coating to heat and pressure comprises subjecting said biocompatible component and said porous coating to a temperature of from about 400°

F. to about 440°

F.

11. A method for applying a porous coating having enhanced adhesion to a biocompatible component, said method comprising the steps of:

providing a biocompatible component formed from a fibrous material;

forming a porous coating on at least a portion of said biocompatible component;

placing said biocompatible component with said porous coating in a flexible container; and

subjecting said biocompatible component and said porous coating to heat and pressure thereby enhancing the adhesion of said porous coating to said biocompatible component.

12. The method according to claim 11, wherein said step of placing said biocompatible component with said porous coating in a flexible container includes the step of placing said biocompatible component in a flexible container formed from silicon.

13. The method according to claim 11, wherein said step of subjecting said biocompatible component and said porous coating to heat and pressure includes the step of heating said flexible container under pressure thereby enhancing the adhesion of said porous coating to said biocompatible component.

14. The method according to claim 11 further comprising the step of placing said biocompatible component with said porous coating within a container including beads prior to subjecting said biocompatible component and said porous coating to heat and pressure.

15. The method according to claim 11 wherein the step of subjecting said biocompatible component and said porous coating to heat and pressure comprises subjecting said biocompatible component and said porous coating to a pressure of greater than about 5000 psi.

16. The method according to claim 11 wherein the step of subjecting said biocompatible component and said porous coating to heat and pressure comprises subjecting said biocompatible component and said porous coating to a temperature of from about 400°

F. to about 440°

F.

17. The method according to claim 11 wherein said step of forming a porous coating on at least a portion of said biocompatible component comprises applying a pad to said biocompatible component.

18. The method according to claim 11 wherein said step of forming a porous coating on at least a portion of said biocompatible component comprises applying a plasma spray to said biocompatible component.