Three-dimensional geometric bio-compatible porous engineered structure for use as a bone mass replacement or fusion augmentation device

• US 6,206,924 B1
• Filed: 10/20/1999
• Issued: 03/27/2001
• Est. Priority Date: 10/20/1999
• Status: Expired due to Term

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Interpore Cross International LLC (Interpore Spine Limited)
• Inventors: Timm, Jens Peter
• Primary Examiner(s): Smith, Jeffrey A.
• Assistant Examiner(s): Robert, Eduardo C.
• Application Number:
  US09/421,723
• Time in Patent Office: 524 Days
• Field of Search: 623/16.11, 623/17.16, 623/18.11, 623/20.16, 623/23.28, 623/23.53, 623/17.11, 606/60, 606/61, 606/62
• US Class Current: 623/17.16
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/442 Intervertebral or spinal discs, e.g. resilient non-disc-shaped intervertebral inflatable pockets A61F2/441; non-disc-shaped intervertebral fusion implants A61F2/4455
• CPC Class Codes: A61F 2/4465 having a circular or kidney shaped cross-section substantially perpendicular to the axis of the spine
• CPC Class Codes: A61F 2002/2835 Bone graft implants for filling a bony defect or an endoprosthesis cavity, e.g. by synthetic material or biological material
• CPC Class Codes: A61F 2002/30133 kidney-shaped or bean-shaped
• CPC Class Codes: A61F 2002/30149 pentagonal
• CPC Class Codes: A61F 2002/30199 Three-dimensional shapes
• CPC Class Codes: A61F 2002/302 toroidal, e.g. rings
• CPC Class Codes: A61F 2002/3028 polyhedral different from parallelepipedal and pyramidal
• CPC Class Codes: A61F 2002/30329 Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: A61F 2002/30593 hollow
• CPC Class Codes: A61F 2002/30622 Implant for fusing a joint or bone material
• CPC Class Codes: A61F 2002/3092 having an open-celled or open-pored structure
• CPC Class Codes: A61F 2220/0025 Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: A61F 2230/0015 Kidney-shaped, e.g. bean-shaped
• CPC Class Codes: A61F 2230/0017 Angular shapes
• CPC Class Codes: A61F 2230/0063 Three-dimensional shapes
• CPC Class Codes: A61F 2230/0065 toroidal, e.g. ring-shaped, doughnut-shaped
• CPC Class Codes: A61F 2310/00011 Metals or alloys
• CPC Class Codes: A61F 2310/00023 Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00179 : Ceramics or ceramic-like structures

Abstract

The invention provides a three-dimensional geometric porous engineered structure for use as a bone mass replacement or fusion augmentation device. The structure is a space-filling, self-supporting structure constructed of rigid filaments joined together to form regular, repeating geometric shapes. The structure supports the skeletal structure as well as the surrounding tissue during rehabilitation and/or bone fusion. Further, the structure provides many open intersticial areas, which are appropriately shaped and sized for bone in-growth. One preferred geometric structure is based on repeating modified dodecahedrons which are built from pentagons. The resulting structure has two transverse planes of bilateral symmetry. Other embodiments include disc shaped structures and structures having open internal areas to allow the possibility of auto graft, allograft, or artificial bone substitute.

Claims

1. A self-supporting bio-compatible porous three dimensional structure for skeletal rehabilitation comprising;

inter-connected rigid filaments collectively defining a series of at least two repeating ordered open 3-dimensional shapes.

2. A self-supporting porous three-dimensional structure a set forth in claim 1, wherein said filaments are connected so as to define repeating geometric shapes.

3. A self-supporting porous three-dimensional structure a set forth in claim 2, wherein at least one of said repeating shapes are five-sided.

4. A self-supporting porous three-dimensional structure a set forth in claim 3, wherein at least one of said repeating shapes is a pentagon.

5. A self-supporting porous three-dimensional structure a set forth in claim 2, wherein at least one of said repeating shapes is 10 sided.

6. A self-supporting porous three-dimensional structure a set forth in claim 5, wherein said shape is a modified dodecahedron.

7. A self-supporting porous three-dimensional structure a set forth in claim 1, wherein the filament is metal.

8. A self-supporting porous three-dimensional structure a set forth in claim 7, wherein the filament is titanium.

9. A self-supporting porous three-dimensional structure a set forth in claim 8, wherein said structure is a bone implant.

10. A self-supporting porous three-dimensional structure a set forth in claim 9, wherein said structure is a three-dimensional, self-supporting, space-filling structure having interconnected solid elements together defining repeating open structures and having no shear planes.

11. An orthopedic implant comprising;

a structure having sides, each side comprising non-random inter-connected 3-dimensionally oriented bio-compatible filaments which define pores, said structure being substantially free from planes predisposed to shear failure.

12. An orthopedic implant as set forth in claim 11 further comprising a void internal to said structure for bone graft or bone substitute.

13. An orthopedic implant as set forth in claim 11, wherein said structure has a top which defines a substantially planar first surface and a bottom, which defines a substantially planar surface substantially parallel to said first surface.

14. An orthopedic implant as set forth in claim 13, wherein said filaments are connected so as to define repeating geometric shapes.

15. An orthopedic implant as set forth in claim 14, wherein at least one of said repeating shapes are five-sided.

16. An orthopedic implant as set forth in claim 15, wherein at least one of said repeating shapes is a pentagon.

17. An orthopedic implant as set forth in claim 16, wherein at least one of said repeating shape is 10 sided.

18. An orthopedic implant as set forth in claim 17, wherein said shape is a modified dodecahedron.

19. An orthopedic implant as set forth in claim 11, wherein the filament is metal.

20. An orthopedic implant as set forth in claim 19, wherein the filament is titanium.

21. An orthopedic implant comprising a structure having a central opening surrounded by at least one mesh wall having pores oriented in three dimensions and comprising bio-compatible, metallic filaments which are interconnected to form discrete sub-components which comprise a repeating pattern of geometric shapes that define said pores.

22. An orthopedic implant as set forth in claim 21 wherein said filaments are connected to form at least two basic repeating geometric configurations.

23. An orthopedic implant as set forth in claim 22 wherein said filaments define multiple planes of symmetry.

24. An orthopedic implant as set forth in claim 23 wherein said filaments are titanium.