Implant with composite coating

• US 7,105,030 B2
• Filed: 07/09/2001
• Issued: 09/12/2006
• Est. Priority Date: 05/14/1998
• Status: Expired due to Fees

• Current Assignee: Consensus Orthopedics, Inc.
• Original Assignee: Hayes Medical Incorporated
• Inventors: Despres, Alfred S. III, Aharonov, Robert R., Ehlers, Peter, Elwood, Eugene J., Andersen, Knut
• Primary Examiner(s): Willse, David H.
• Assistant Examiner(s): GHERBI, SUZETTE JAIME J
• Application Number:
  US09/901,310
• Publication Number:
  US 20020016635A1
• Time in Patent Office: 1,891 Days
• Field of Search: 623/23.53, 427/2.26, 427/2.27, 427/23.36
• US Class Current: 623/23.36
• 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 2/36 Femoral heads ; Femoral endoprostheses
• 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 2/3859 Femoral components
• CPC Class Codes: A61F 2002/30016 differing in hardness, e.g. Vickers, Shore, Brinell
• CPC Class Codes: A61F 2002/30906 shot- sand- or grit-blasted
• CPC Class Codes: A61F 2002/30925 etched
• CPC Class Codes: A61F 2002/30929 having at least two superposed coatings
• CPC Class Codes: A61F 2002/30968 Sintering
• CPC Class Codes: A61F 2002/3097 using laser
• CPC Class Codes: A61F 2002/3611 Heads or epiphyseal parts of femur
• CPC Class Codes: A61F 2002/3625 Necks
• CPC Class Codes: A61F 2002/3631 with an integral complete or partial peripheral collar or bearing shoulder at its base
• CPC Class Codes: A61F 2002/365 Connections of heads to necks
• CPC Class Codes: A61F 2250/0019 differing in hardness, e.g. Vickers, Shore, Brinell
• CPC Class Codes: A61F 2310/00017 Iron- or Fe-based alloys, e.g. stainless steel
• CPC Class Codes: A61F 2310/00023 Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00029 : Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• CPC Class Codes: A61F 2310/00131 : Tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00179 : Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00407 : Coating made of titanium or of Ti-based alloys
• CPC Class Codes: A61F 2310/00485 : Coating made of zirconium or Zr-based alloys
• CPC Class Codes: A61F 2310/00491 : Coating made of niobium or Nb-based alloys
• CPC Class Codes: A61F 2310/00538 : Coating made of hafnium or Hf-based alloys
• CPC Class Codes: A61F 2310/00544 : Coating made of tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00574 : Coating or prosthesis-covering structure made of carbon, e.g. of pyrocarbon
• CPC Class Codes: A61F 2310/0058 : Coating made of diamond or of diamond-like carbon DLC
• CPC Class Codes: A61F 2310/00796 : Coating or prosthesis-covering structure made of a phosphorus-containing compound, e.g. hydroxy(l)apatite
• CPC Class Codes: A61F 2310/00976 : Coating or prosthesis-covering structure made of proteins or of polypeptides, e.g. of bone morphogenic proteins BMP or of transforming growth factors TGF
• CPC Class Codes: A61L 27/306 : Other specific inorganic materials not covered by A61L27/303 - A61L27/32
• CPC Class Codes: A61P 19/00 : Drugs for skeletal disorders

Abstract

Systems and methods are described for implants with composite coatings to promote tissue in-growth and/or on-growth. An implant includes: a substrate; a structured surface formed on at least a portion of the substrate; and a biocompatible coating deposited on at least a fraction of the structured surface. The systems and methods provide advantages in that the implant has good biocompatibility while the biocompatible coating has good strength.

Claims

1. An implant, comprising:

a substrate;

a structured surface formed on at least a portion of said substrate; and

a biocompatible coating deposited on at least a fraction of said structured surface;

wherein said structured surface includes a plurality of undercuts, and said biocompatible coating coats said plurality of undercuts in said structured surface;

wherein said coating is formed by a thin film technique adapted to deposit said coating on line-of-sight hidden surfaces within said plurality of undercuts of said structured surface; and

wherein said structured surface is porous and said biocompatible coating coats interconnected pores within said structured surface.

2. The implant of claim 1, wherein said biocompatible coating is more biocompatible than said structured surface.

3. The implant of claim 1, wherein said biocompatible coating is more biocompatible than said substrate.

4. The implant of claim 1, wherein said biocompatible coating is softer than said structured surface.

5. The implant of claim 1, wherein said biocompatible coating is softer than said substrate.

6. The implant of claim 1, wherein said thin film technique includes at least one deposition process selected from the group consisting of physical vapor deposition and chemical vapor deposition.

7. The implant of claim 1, wherein said substrate includes at least one material selected from the group consisting of carbon-composite, stainless steel, cobalt-chromium, titanium alloy, tantalum, and ceramic.

8. The implant of claim 1, wherein said biocompatible coating includes at least one material selected from the group consisting of titanium, tantalum, carbon, calcium phosphate, zirconium, niobium, hafnium, hydroxyapatite, and tissue in-growth and/or on-growth facilitating proteins.

9. The implant of claim 1, wherein said biocompatible coating includes multi-layers.

10. The implant of claim 1, wherein said biocompatible coating includes nano-layers.

11. The implant of claim 1, wherein said implant is an orthopedic prosthesis.

12. A method for orthopedic surgery which comprises surgically positioning said implant of claim 1, within a vertebrate in need thereof.

13. An osteoconductive process, comprising contacting a bone under in vivo conditions with said implant of claim 1.

18. The composition of claim 6, wherein said biocompatible coating is more biocompatible than the substrate.

19. The composition of claim 6, wherein said biocompatible coating is softer than the substrate.

14. An implant, comprising:

a substrate;

a structured surface formed on at least a portion of said substrate; and

a biocompatible coating deposited on at least a fraction of said structured surface;

wherein said structured surface includes a plurality of undercuts, and said biocompatible coating coats said plurality of undercuts in said structured surface;

wherein said coating is formed by a thin film technique adapted to deposit said coating on line-of-sight hidden surfaces within said plurality of undercuts of said structured surface; and

wherein said structured surface is defined by a material that includes a plurality of particles that are sintered together to form a continuous porous phase.

15. An implant, comprising:

a substrate;

a structured surface formed on at least a portion of said substrate; and

a biocompatible coating deposited on at least a fraction of said structured surface;

wherein said structured surface includes a plurality of undercuts, and said biocompatible coating coats said plurality of undercuts in said structured surface;

wherein said coating is formed by a thin film technique adapted to deposit said coating on line-of-sight hidden surfaces within said plurality of undercuts of said structured surface; and

wherein said structured surface is prepared by at least one method selected from the group consisting of sintering, flame spraying, acid etching, grit blasting, casting-in, forging-in, laser texturing, and micromachining.

16. A composition for an implant, comprising:

a biocompatible material coated on a structured surface affixed to a substrate;

wherein the structured surface includes a plurality of undercuts, and said biocompatible material coats the plurality of undercuts in the structured surface;

wherein the coating is formed by a thin film technique adapted to deposit the coating on line-of-sight hidden surfaces within said plurality of undercuts of the structured surface; and

wherein the structured surface is porous and said biocompatible material coats interconnected pores within the structured surface.

17. The composition of claim 16, wherein said biocompatible coating is more biocompatible than the structured surface.

20. The composition of claim 16, wherein said biocompatible coating is softer than the substrate.

21. The composition of claim 16, wherein the thin film technique includes at least one deposition process selected from the group consisting of physical vapor deposition and chemical vapor deposition.

22. The composition of claim 16, wherein the substrate includes at least one material selected from the group consisting of carbon-composite, stainless steel, cobalt-chromium, titanium alloy, tantalum, and ceramic.

23. The composition of claim 16, wherein said biocompatible coating includes at least one material selected from the group consisting of titanium, tantalum, carbon, calcium phosphate, zirconium, niobium, hafnium, hydroxyapetite, and tissue in-growth and/or on-growth facilitating proteins.

24. The composition of claim 16, wherein said biocompatible coating includes multi-layers.

25. The composition of claim 16, wherein said biocompatible coating includes nano-layers.

26. An osteoconductive process, comprising contacting a bone under in vivo conditions with the composition of claim 16.

27. An orthopedic implant, comprising the composition of claim 16.

28. A method for orthopedic surgery which comprises positioning the composition of claim 16 within a vertebrate in need thereof.

29. A composition for an implant, comprising:

a biocompatible material coated on a structured surface affixed to a substrate;

wherein the structured surface includes a plurality of undercuts, and said biocompatible material coats the plurality of undercuts in the structured surface;

wherein the coating is formed by a thin film technique adapted to deposit the coating on line-of-sight hidden surfaces within the plurality of undercuts of the structured surface; and

wherein the structured surface is defined by a material that includes a plurality of particles that are sintered together to form a continuous porous phase.

30. A composition for an implant, comprising:

a biocompatible material coated on a structured surface affixed to a substrate;

wherein the structured surface includes a plurality of undercuts, and said biocompatible material coats the plurality of undercuts in the structured surface;

wherein the coating is formed by a thin film technique adapted to deposit the coating on line-of-sight hidden surfaces within the plurality of undercuts of the structured surface; and

wherein the structured surface is prepared by at least one method selected from the group consisting of sintering, flame spraying, acid etching, grit blasting, casting-in, forging-in, laser texturing, and micromachining.

31. An implant, comprising:

a substrate;

a structured surface formed on a portion of said substrate; and

a biocompatible coating deposited on at least a fraction of said structured surface;

wherein said structured surface includes a plurality of undercuts, and said biocompatible coating coats the plurality of undercuts in said structured surface;

wherein said coating is formed by a thin film technique adapted to deposit said coating on line-of-sight hidden surfaces within the plurality of undercuts of said structured surface;

wherein the portion of said substrate is to be fixed with tissue-in-growth and/or on-growth for stability; and

wherein said structured surface is defined by a material that includes a plurality of particles that are sintered together to form a continuous porous phase.

32. The implant of claim 31, wherein said biocompatible coating is more biocompatible than said structured surface.

33. The implant of claim 31, wherein said biocompatible coating is more biocompatible than said substrate.

34. The implant of claim 31, wherein said biocompatible coating is softer than said structured surface.

35. The implant of claim 31, wherein said biocompatible coating is softer than said substrate.

36. The implant of claim 31, wherein the thin film technique includes at least one deposition process selected from the group consisting of physical vapor deposition and chemical vapor deposition.

37. The implant of claim 31, wherein said structured surface is porous and said biocompatible coating coats interconnected pores within said structured surface.

38. The implant of claim 31, wherein said substrate includes at least one material selected from the group consisting of carbon-composite, stainless steel, cobalt-chromium, titanium alloy, tantalum, and ceramic.

39. The implant of claim 31, wherein said biocompatible coating includes at least one material selected from the group consisting of titanium, tantalum, carbon, calcium phosphate, zirconium, niobium, hafnium, hydroxyapetite, and tissue in-growth and/or on-growth facilitating proteins.

40. The implant of claim 31, wherein said biocompatible coating includes multi-layers.

41. The implant of claim 31, wherein said biocompatible coating includes nano-layers.

42. The implant of claim 31, wherein the implant is an orthopedic prosthesis.

43. A method for orthopedic surgery which comprises surgically positioning the implant of claim 31 within a vertebrate in need thereof.

44. An osteoconductive process, comprising contacting a bone under in vivo conditions with the implant of claim 31.

45. An implant, comprising:

a substrate;

a structured surface formed on a portion of said substrate; and

a biocompatible coating deposited on at least a fraction of said structured surface;

wherein said structured surface includes a plurality of undercuts, and said biocompatible coating coats the plurality of undercuts in said structured surface;

wherein said coating is formed by a thin film technique adapted to deposit said coating on line-of-sight hidden surfaces within the plurality of undercuts of said structured surface;

wherein the portion of said substrate is to be fixed with tissue-in-growth and/or on-growth for stability; and

wherein said structured surface is prepared by at least one method selected from the group consisting of sintering, flame spraying, acid etching, grit blasting, casting-in, forging-in, laser texturing, and micromachining.

46. An implant, comprising:

a substrate;

a structured surface formed on at least a portion of said substrate; and

a biocompatible coating deposited on at least a fraction of said structured surface;

wherein said structured surface is defined by a material that includes a plurality of particles that are sintered together to form a continuous porous phase.

47. A composition for an implant, comprising:

a biocompatible material coated on a structured surface defined by a substrate;

wherein said structured surface is defined by a material that includes a plurality of particles that are sintered together to form a continuous porous phase.

48. An implant comprising:

a substrate;

a structured surface formed on a portion of said substrate; and

a biocompatible coating deposited on at least a fraction of said structured surface,

wherein said portion of said substrate is to be fixed with tissue in-growth and/or on-growth for stability; and

wherein said structured surface is defined by a material that includes a plurality of particles that are sintered together to form a continuous porous phase.

49. An implant, comprising:

a substrate;

a structured surface formed on at least a portion of said substrate; and

a biocompatible coating deposited on at least a fraction of said structured surface;

wherein said structured surface is defined by a material that includes a plurality of particles that are sintered together to form a continuous porous phase; and

said biocompatible material penetrates the continuous porous phase through said structured surface to said substrate so as to coat the continuous porous phase on line-of-sight hidden surfaces within said structured surface.

50. A composition for an implant, comprising:

a biocompatible material coated on a structured surface fixed on a substrate, wherein the structured surface either

(i) includes a plurality of undercuts and said biocompatible coating coats the plurality of undercuts in the structured surface, or

(ii) is porous and said biocompatible coating coats interconnected pores within the structured surface; and

wherein the structured surface is defined by a material that includes a plurality of particles that are sintered together to form a continuous porous phase, and said biocompatible material penetrates through the structured surface to the substrate so as to coat the continuous porous phase on line-of-sight hidden surfaces within the structured surface.

51. An implant, comprising:

a substrate;

a structured surface formed on a portion of said substrate; and

a biocompatible coating deposited on at least a fraction of said structured surface;

wherein the portion of said substrate is to be fixed with tissue in-growth and/or on-growth for stability;

wherein said structured surface either

(i) includes a plurality of undercuts and said biocompatible coating coats said plurality of undercuts in said structured surface, or

(ii) is porous and said biocompatible coating coats interconnected pores within said structured surface; and

wherein said structured surface is defined by a material that includes a plurality of particles that are sintered together to form a continuous porous phase, and said biocompatible coating penetrates through said structured surface to said substrate so as to coat said continuous porous phase on line-of-sight hidden surfaces within said structured surface.