Enhanced biocompatible implants and alloys

• US 6,539,607 B1
• Filed: 09/13/2000
• Issued: 04/01/2003
• Est. Priority Date: 02/10/1999
• Status: Expired due to Fees

• Current Assignee: ATI Properties Incorporated (Allegheny Technologies Incorporated), University of North Carolina At Charlotte (University of North Carolina System)
• Original Assignee: ATI Properties Incorporated (Allegheny Technologies Incorporated), University of North Carolina At Charlotte (University of North Carolina System)
• Inventors: Fehring, Thomas K., Chaffin, John Harvie III, Kennedy, Richard Lee
• Primary Examiner(s): Vidovich, Gregory M.
• Assistant Examiner(s): JIMENEZ, MARC QUEMUEL
• Application Number:
  US09/661,525
• Time in Patent Office: 930 Days
• Field of Search: 295/57, 295/58, 295/59, 623/16, 623/18, 623/19, 623/20, 623/21, 623/22, 623/23, 623/17, 623/11.11, 623/16.11, 623/23.75, 623/23.76, 623/23.51, 623/23.61, 623/18.11, 623/39, 420/435, 148/647, 428/687
• US Class Current: 29/557
• 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 2/468 Testing instruments for artificial joints for testing non-implantable prostheses A61F2/76
• CPC Class Codes: A61F 2002/30934 Special articulating surfaces
• CPC Class Codes: A61F 2002/3611 Heads or epiphyseal parts of femur
• CPC Class Codes: A61F 2310/00029 Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• CPC Class Codes: A61L 27/045 Cobalt or cobalt alloys
• CPC Class Codes: Y10T 29/49995 Shaping one-piece blank by removing material

Abstract

The invention provides improved biocompatible implant alloys and methods of constructing artificial implants having improved long term wear properties. Cobalt-base biocompatible implant alloys provided according to the invention are essentially free of carbide, nitride and sigma second phase particles, and can have hardness and strength properties equivalent to or greater than the standard CoCrMo alloy with significantly improved fatigue life and superior frictional contact properties with UHMWPE. Artificial implant constructions and methods provided according to another aspect of the invention are capable of eliminating latent defects that can promote long term failure of joint implants.

Claims

1. A method of manufacturing a cobalt-base alloy implant component comprising the steps:

providing a bar stock of biocompatible cobalt-base alloy; and

precision machining the bar stock under conditions sufficient to remove metal from said bar stock to form an implant component of predetermined shape without deforming the structure of said alloy sufficiently that the mean average increase in surface defects of a size above 5 micrometers is greater than 10 when said implant component is subjected to accelerated chemical aging. by immersing the component in human synovial fluid inside a sealed pressure vessel and heating the pressure vessel to a temperature of 159°

C. plus or minus 1°

C. for 8.6 days.

2. The method of claim 1 wherein said precision machining step is conducted without deforming the structure of said alloy sufficiently that the mean average increase in surface defects of a size above 5 micrometers is greater than 7.5 when said implant component is subjected to said accelerated chemical aging.

3. The method of claim 1 wherein said precision machining step is conducted without deforming the structure of said alloy sufficiently that the mean average increase in surface defects of a size above 5 micrometers is greater than 3.5 when said implant component is subjected to said accelerated chemical aging.

4. The method of claim 1, wherein said precision machining step is conducted without deforming the structure of said alloy sufficiently that the mean average increase in surface defects of a size above 5 micrometers is greater than 2 when said implant component is subjected to said accelerated chemical aging.

5. The method of claim 1 wherein said precision machining step is conducted without deforming the structure of said alloy sufficiently that the mean average increase in surface defects of a size above 5 micrometers is greater than 1 when said implant component is subjected to said accelerated chemical aging.

6. The method of claim 2 wherein said alloy consists essentially of:

from about 26 to about 28 weight percent chromium;

from about 5 to about 6 weight percent molybdenum;

up to about 1 weight percent manganese;

up to about 1 weight percent nickel;

up to about 0.75 weight percent iron;

up to about 0.07 weight percent carbon;

the remainder of the alloy being cobalt and impurities.

7. The method of claim 6, wherein said alloy further comprises nitrogen in an amount sufficient to increase hardness of said alloy up to about 0.25 weight percent, less than about 0.10% Si;

and less than about 0.02% Ti.

8. The method of claim 7 wherein said alloy is essentially free of carbide, nitride and sigma second phase particles.

9. The method of claim 6, wherein said precision machining step is conducted by a technique selected from the group consisting of precision single point turning operations, chemical machining operations, electrochemical machining operations, laser beam machine operations, and electrochemical grinding operations.