Method of surface oxidizing zirconium and zirconium alloys and resulting product
First Claim
1. A prosthesis for implantation in a patient, comprising:
- (a) a prosthesis body formed of zirconium or zirconium alloy comprising an implant portion for inserting into the body tissue of the patient, at least a part of said zirconium or zirconium alloy having a single phase crystalline structure;
(b) a bearing surface comprising at least one condyle on the prosthesis body;
(c) a tibial component formed of an organic polymer or polymer based composite and adapted to cooperate with the bearing surface; and
(d) a coating of blue-black or black oxidized zirconium of uniform thickness directly on the bearing surface of the condyle for reducing wear of the organic polymer or polymer-based composite component prepared by the process comprising the steps of altering the surface roughness of said zirconium or zirconium alloy having a single phase crystalline structure and uniform composition and subsequently oxidizing said zirconium or zirconium alloy.
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Abstract
A coating of blue-black or black oxidized zirconium of uniform and controlled thickness on a zirconium or zirconium alloy material is accomplished through the use of a single phase crystalline material substrate having an altered surface roughness. An oxidized zirconium coating of uniform and controlled thickness is especially useful on orthopedic implants of zirconium or zirconium-based alloys to provide low friction, highly wear resistant surfaces on artificial joints, such as, but not limited to, hip joints, knee joints, shoulders, elbows, and spinal implants. The uniformly thick oxidized zirconium surface of controlled depth on prostheses provide a barrier against implant corrosion caused by ionization of the metal prostheses. The invention is also useful in non-articulating implant devices such as bone plates, bone screws, etc.
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Citations
27 Claims
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1. A prosthesis for implantation in a patient, comprising:
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(a) a prosthesis body formed of zirconium or zirconium alloy comprising an implant portion for inserting into the body tissue of the patient, at least a part of said zirconium or zirconium alloy having a single phase crystalline structure; (b) a bearing surface comprising at least one condyle on the prosthesis body; (c) a tibial component formed of an organic polymer or polymer based composite and adapted to cooperate with the bearing surface; and (d) a coating of blue-black or black oxidized zirconium of uniform thickness directly on the bearing surface of the condyle for reducing wear of the organic polymer or polymer-based composite component prepared by the process comprising the steps of altering the surface roughness of said zirconium or zirconium alloy having a single phase crystalline structure and uniform composition and subsequently oxidizing said zirconium or zirconium alloy. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A prosthesis for implantation in a patient, comprising:
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(a) a prosthesis body formed of zirconium or zirconium alloy comprising an implant portion for insertion into the body tissue of the patient, at least a part of said zirconium or zirconium alloy having a single phase crystalline structure; (b) a bearing surface on the prosthesis body, the bearing surface being sized and shaped to engage or cooperate with a second bearing surface on another prosthesis portion, said second bearing surface being formed of an organic polymer or polymer-based composite; and (c) a coating of blue-black or black oxidized zirconium of uniform thickness, said coating having a thickness of up to about 20 microns on the hearing surface of the prosthesis body for reducing wear on the organic polymer or polymer-based second bearing surface of said another prosthesis portion, prepared by the process comprising the steps of altering the surface roughness of said zirconium or zirconium alloy having a single phase crystalline structure and uniform composition and subsequently oxidizing said zirconium or zirconium alloy. - View Dependent Claims (8, 9, 10, 11, 12, 13)
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14. A prosthesis for implantation in a patient, comprising:
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(a) a prosthesis body formed of zirconium or zirconium alloy comprising an implant portion for inserting into the body tissue of the patient, at least a part of said zirconium or zirconium alloy having a single phase crystalline structure; (b) a bearing surface on the prosthesis body; (c) a counter-bearing surface formed of an organic polymer or polymer-based composite and adapted to cooperate with the bearing surface; and (d) a coating of blue-black or black oxidized zirconium uniform thickness directly on the bearing surface for reducing wear of the organic polymer or polymer-based composite counter-bearing surface prepared by the process comprising the steps of altering the surface roughness of a zirconium or zirconium alloy having a single phase crystalline structure and uniform composition and subsequently oxidizing said zirconium or zirconium alloy. - View Dependent Claims (15, 16, 17, 18, 19)
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20. A prosthesis for implantation in a patient, comprising:
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(a) a prosthesis body having an external surface at least a portion of which is formed of zirconium or zirconium alloy, at least a van of said zirconium or zirconium alloy having single phase crystalline structure and uniform composition and an altered surface roughness; and (b) a blue-black or black oxidized zirconium coating of uniform thickness formed on said portion of the external surface by inducing an altered surface roughness on at least said portion of the external surface and subjecting said portion of the external surface of said prosthesis body to an oxidation process. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27)
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Specification