Medical implant device and method for making same

• US 5,807,407 A
• Filed: 05/04/1992
• Issued: 09/15/1998
• Est. Priority Date: 05/04/1992
• Status: Expired due to Term

• Current Assignee: Hercules Incorporated (Ashland Global Holdings, Inc.), Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Incorporated (Zimmer Biomet Holdings, Inc.)
• Inventors: Blaschke, Richard Craig, England, Garry Lee
• Primary Examiner(s): ISABELLA, DAVID J
• Application Number:
  US07/878,163
• Time in Patent Office: 2,325 Days
• Field of Search: 623/16, 623/18, 427/2
• US Class Current: 128/898
• 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 2/30965 Reinforcing the prosthesis by embedding particles or fibres during moulding or dipping
• CPC Class Codes: A61F 2/32 for the hip
• CPC Class Codes: A61F 2/3662 Femoral shafts
• 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 2/3676 Distal or diaphyseal parts of shafts
• CPC Class Codes: A61F 2002/30009 differing in fibre orientations
• 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 2002/30322 differing in surface structures
• CPC Class Codes: A61F 2002/30906 shot- sand- or grit-blasted
• CPC Class Codes: A61F 2002/30929 having at least two superposed coatings
• CPC Class Codes: A61F 2002/3611 Heads or epiphyseal parts of femur
• CPC Class Codes: A61F 2002/3625 Necks
• CPC Class Codes: A61F 2210/0071 thermoplastic
• CPC Class Codes: A61F 2250/0026 differing in surface structures
• CPC Class Codes: A61F 2250/0028 differing in fibre orientations
• 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: A61L 27/30 Inorganic materials
• CPC Class Codes: A61L 27/443 : with carbon fillers
• CPC Class Codes: C08L 71/12 : Polyphenylene oxides
• CPC Class Codes: C08L 81/06 : Polysulfones; Polyethersulfones
• CPC Class Codes: C23C 4/00 : Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge build-up welding B23K, e.g. B23K5/18, B23K9/04
• CPC Class Codes: Y10S 623/901 : Method of manufacturing prosthetic device

Abstract

A medical implant device being operable to replace at least a portion of the natural joint in a human. The medical implant device includes a structural member being composed of a composite material. The medical implant device further includes a metallic porous coating disposed on at least a portion of the exterior of the structural member.

Claims

1. A method for manufacturing a medical implant device which is operable to replace at least a portion of a natural joint in a human, said method comprising the steps of:

forming a structural member from a composite material, said structural member having an exterior; and

applying a metallic porous coating to at least a portion of the exterior of said structural member, said step of applying a metallic porous coating includes the step of securing a thermally sprayed metal to said structural member by melting at least a portion of the exterior of said structural member.

2. The medical implant device manufactured by the method set forth in claim 1.

3. The method for manufacturing a medical implant device of claim 1, wherein said step of forming a structural member includes the step of orienting fibers in said structural member to control the structural modulus of said structural member.

4. The method for manufacturing a medical implant device of claim 1, wherein said step of forming a structural member includes the step of forming said structural member from biocompatible thermoplastic selected from the group consisting of polysulfone, polyether ether ketone, and poly aryl ether ketone.

5. The method of claim 4, wherein said step of applying a metallic porous coating comprises the step of applying to said structural member a porous layer of an alloy of a material selected from the group consisting of titanium and cobalt chrome.

6. The method for manufacturing a medical implant device of claim 1, wherein said step of applying a metallic porous coating includes the steps of repeatedly:

(a) applying a plasma spray to a said structural member, said plasma spray including a metal used in forming said metallic porous coating, and

(b) removing said plasma spray from said structural member,

whereby said metallic porous coating is secured to said composite material by melting portions of the exterior of said structural member.

7. The method of claim 1, further comprising the additional step of grit blasting said structural member before said metallic coating is applied.

8. A porous coated medical implant device prepared by the process of:

forming a structural member from a composite material having fibers oriented to obtain a desired structural modulus, said structural member having an exterior;

locating said medical implant device in a spray chamber; and

applying a plasma spray having a metallic material to said structural member so as to secure said metallic material to said structural member.

9. The porous coated medical implant device of claim 8, wherein:

said structural member is formed from a material selected from the group consisting of polysulfone, polyether ether ketone, and poly arly ether ketone; and

said metallic material is formed from an alloy of a material selected from the group consisting of titanium and cobalt chrome.

10. The porous coated medical implant device of claim 9, wherein said step of applying a plasma spray includes the steps of repeatedly:

(a) applying said plasma spray to said structural member, and

(b) removing said plasma spray from said structural member,

whereby said metallic material is secured to said composite material by melting a portion of the exterior of said structural member.

11. The porous coated medical implant device of claim 10, wherein said structural member includes a layer of thermoplastic resin.

12. The porous coated medical implant device of claim 11, further prepared by the additional step of grit blasting said structural member before said plasma spray is applied to said structural member.

13. The porous coated medical implant of claim 12, wherein said porous coated medical implant forms a portion of a hip joint prosthesis.