Living body-supporting member and preparation process thereof

• US 6,010,336 A
• Filed: 12/20/1995
• Issued: 01/04/2000
• Est. Priority Date: 12/26/1994
• Status: Expired due to Term

• Current Assignee: Kyocera Corporation
• Original Assignee: Kyocera Corporation
• Inventors: Kitano, Hiroyuki, Shimotoso, Toshihiko, Terui, Akira
• Primary Examiner(s): Lewis, Ralph A.
• Application Number:
  US08/580,018
• Time in Patent Office: 1,476 Days
• Field of Search: 433/173, 433/201.1, 623/16, 606/76, 606/77
• US Class Current: 433/201.1
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/30261 parallelepipedal
• CPC Class Codes: A61F 2002/30915 made of a stack of bonded perforated sheets, grids or wire meshes
• 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 2230/0082 parallelepipedal
• CPC Class Codes: A61F 2250/0024 made from both porous and non-porous parts, e.g. adjacent parts
• CPC Class Codes: A61F 2310/00293 containing a phosphorus-containing compound, e.g. apatite
• CPC Class Codes: A61L 27/10 Ceramics or glasses
• CPC Class Codes: A61L 27/12 Phosphorus-containing materials, e.g. apatite

Abstract

A living body-supporting member having a surface layer with multiple pores regularly arranged therein, in which the porous portions constituting the living body-supporting member are made of ceramics giving no harm to a human body. And a method to perforate multiple pores in a green sheet made of the ceramics, to laminate the green sheets so that pores communicate with each other, and to fire it. The living body-supporting member is coupled with the bone, and there is no risk that it may drop from the supporting portion. Even if the substrate is composed of ceramics, the substrate and the surface layer can be integrally coupled with each other, thereby there is no risk that both of them are separated. Furthermore, according to the above method, the pore shapes of the porous body can be preliminarily designed so that pores communicate with each other while being displaced for every certain depth, and it can be accurately controlled in the production thereof.

Claims

1. A process of preparing a living body supporting member, comprising:

providing a plurality of green sheets of biologically inert ceramic material, each of the plurality of green sheets having a thickness between about 100 and 1000 microns,

perforating each of the plurality of green sheets with a plurality of regularly spaced pores,

laminating the plurality of green sheets so that the plurality of regularly spaced pores of each green sheet is displaced relative to the plurality of regularly spaced pores of at least one adjacent green sheet and the plurality of regularly spaced pores of each green sheet communicates with the plurality of regularly spaced pores of at least one adjacent green sheet, and

firing the laminated plurality of green sheets.

2. A process of preparing a living body supporting member according to claim 1, further comprising a step of bonding the plurality of laminated green sheets to a plate of biologically inert ceramic material thicker than each of the plurality of green sheets.

3. A process of preparing a living body supporting member according to claim 2, wherein the plate and the plurality of laminated green sheets use the same biologically inert ceramic material.

4. A process of preparing a living body supporting member according to claim 3, further comprising a step of firing the plurality of laminated green sheets bonded to the plate to form a two-layer structure including a porous portion formed from the plurality of laminated green sheets and a dense portion formed from the plate.

5. A process of preparing a living body supporting member according to claim 1, further comprising:

a step of dividing the plurality of green sheets into first and second groups;

a step of perforating each of the green sheets in the first group with first pores at a first pitch, each of the first pores having a first diameter;

a step of perforating each of the green sheets in the second group with pores at a second pitch greater than the first pitch, each of the second pores having a second diameter; and

a step of alternately laminating the perforated green sheets in the first group and the perforated green sheets in the second group.

6. A process of preparing a living body supporting member according to claim 5, wherein the second diameter is greater than the first diameter.

7. A process of preparing a living body supporting member according to claim 6, further comprising a step of bonding the plurality of laminated green sheets to a plate of biologically inert ceramic material thicker than each of the plurality of green sheets.

8. A process of preparing a living body supporting member according to claim 7, wherein the plate and the plurality of laminated green sheets use the same biologically inert ceramic material.

9. A process of preparing a living body supporting member according to claim 8, further comprising a step of firing the plurality of laminated green sheets bonded to the plate to form a two-layer structure including a porous portion formed from the plurality of laminated green sheets and a dense portion formed from the plate.

10. A process of preparing a living body supporting member, comprising:

providing a plurality of green sheets of biologically inert ceramic material, each of the plurality of green sheets having a thickness between about 100 and 1000 microns,

perforating each of the plurality of green sheets with a plurality of regularly spaced slits,

laminating the plurality of green sheets so that the plurality of regularly spaced slits of each green sheet is disposed transverse with respect to the plurality of regularly spaced slits of at least one adjacent green sheet and the plurality of regularly spaced slits of each green sheet communicates with the plurality of regularly spaced slits of at least one adjacent green sheet, and

firing the laminated plurality of green sheets.

11. A process of preparing a living body supporting member according to claim 10, wherein the regularly spaced slits of each of the plurality of green sheets are perforated to extend across substantially the width of each of the plurality of green sheets.

12. A process of preparing a living body supporting member according to claim 11, wherein the plurality of green sheets are laminated so that the plurality of regularly spaced slits of each green sheet is disposed transverse with respect to the plurality of regularly spaced slits of an adjacent green sheet.

13. A process of preparing a living body supporting member according to claim 10, further comprising a step of bonding the plurality of laminated green sheets to a plate of biologically inert ceramic material thicker than each of the plurality of green sheets.