Assembled non-random foams

• US 7,208,222 B2
• Filed: 07/23/2004
• Issued: 04/24/2007
• Est. Priority Date: 07/24/2003
• Status: Active Grant

• Current Assignee: Tecomet, Inc.
• Original Assignee: Viasys Healthcare Incorporated (Cardinal Health, Inc.)
• Inventors: Lynch, Robert, Rolfe, Jonathan L., Amrich, Mark P., Cairns, Robert, Buturlia, Joseph A., Gerry, Michael
• Primary Examiner(s): McNeil; Jennifer
• Assistant Examiner(s): BALDWIN, GORDON
• Application Number:
  US10/898,659
• Publication Number:
  US 20050112397A1
• Time in Patent Office: 1,005 Days
• Field of Search: 428/304.4, 428/131, 428/134, 428/137, 428/138, 428/310.5
• US Class Current: 428/304.4
• CPC Class Codes: A61B 17/562 Implants for placement in joint gaps without restricting joint motion, e.g. to reduce arthritic pain
• CPC Class Codes: A61B 17/7044 also having plates, staples or washers bearing on the vertebrae
• CPC Class Codes: A61B 17/8605 Heads, i.e. proximal ends projecting from bone
• CPC Class Codes: A61B 17/866 Material or manufacture
• CPC Class Codes: A61B 17/8695 Washers surrounding screw head in plate hole A61B17/8047, between bone plate and bone A61B17/8028
• CPC Class Codes: A61C 8/0012 characterised by the material or composition, e.g. ceramics, surface layer, metal alloy use of specific materials A61K6/00
• CPC Class Codes: A61F 2/0811 Fixation devices for tendons or ligaments
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2/32 for the hip
• CPC Class Codes: A61F 2/34 Acetabular cups
• CPC Class Codes: A61F 2/36 Femoral heads ; Femoral endoprostheses
• 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 2/3676 Distal or diaphyseal parts of shafts
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/3877 Patellae or trochleae
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/4081 Glenoid components, e.g. cups
• CPC Class Codes: A61F 2/4241 for hands, e.g. fingers
• 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 2/4455 : for the fusion of spinal bodies, e.g. intervertebral fusion of adjacent spinal bodies, e.g. fusion cages intervertebral discs A61F2/442
• CPC Class Codes: A61F 2/447 : substantially parallelepipedal, e.g. having a rectangular or trapezoidal cross-section
• CPC Class Codes: A61F 2/481 : Acoustic or audible means
• CPC Class Codes: A61F 2002/087 : Anchor integrated into tendons, e.g. bone blocks, integrated rings
• CPC Class Codes: A61F 2002/0888 : Anchor in or on a blind hole or on the bone surface without formation of a tunnel
• CPC Class Codes: A61F 2002/30004 : the prosthesis being made from materials having different values of a given property at different locations within the same prosthesis
• CPC Class Codes: A61F 2002/30009 : differing in fibre orientations
• CPC Class Codes: A61F 2002/30011 : differing in porosity
• CPC Class Codes: A61F 2002/30014 : differing in elasticity, stiffness or compressibility
• CPC Class Codes: A61F 2002/30062 : (bio)absorbable, biodegradable, bioerodable, (bio)resorbable, resorptive
• CPC Class Codes: A61F 2002/30069 : elastomeric
• CPC Class Codes: A61F 2002/30113 : circular
• CPC Class Codes: A61F 2002/30125 : elliptical or oval
• CPC Class Codes: A61F 2002/3013 : figure-"8"- or hourglass-shaped
• CPC Class Codes: A61F 2002/30143 : hexagonal
• CPC Class Codes: A61F 2002/30149 : pentagonal
• CPC Class Codes: A61F 2002/30151 : rhomboidal or parallelogram-shaped
• CPC Class Codes: A61F 2002/30153 : rectangular
• CPC Class Codes: A61F 2002/30154 : square
• CPC Class Codes: A61F 2002/30199 : Three-dimensional shapes
• CPC Class Codes: A61F 2002/30224 : cylindrical
• CPC Class Codes: A61F 2002/30227 : arched, domed or vaulted
• CPC Class Codes: A61F 2002/30235 : tubular, e.g. sleeves
• CPC Class Codes: A61F 2002/30261 : parallelepipedal
• CPC Class Codes: A61F 2002/3028 : polyhedral different from parallelepipedal and pyramidal
• CPC Class Codes: A61F 2002/30293 : Cylindrical body made by spirally rolling up a sheet or a strip around itself
• CPC Class Codes: A61F 2002/30299 : umbrella-shaped or mushroom-shaped
• CPC Class Codes: A61F 2002/30451 : soldered or brazed or welded
• CPC Class Codes: A61F 2002/30563 : having elastic means or damping means, different from springs, e.g. including an elastomeric core or shock absorbers
• CPC Class Codes: A61F 2002/30593 : hollow
• CPC Class Codes: A61F 2002/30649 : Ball-and-socket joints
• CPC Class Codes: A61F 2002/30677 : Means for introducing or releasing pharmaceutical products, e.g. antibiotics, into the body
• CPC Class Codes: A61F 2002/3071 : Identification means; Administration of patients
• CPC Class Codes: A61F 2002/30785 : parallel
• CPC Class Codes: A61F 2002/30878 : with non-sharp protrusions, for instance contacting the bone for anchoring, e.g. keels, pegs, pins, posts, shanks, stems, struts
• CPC Class Codes: A61F 2002/30892 : parallel
• CPC Class Codes: A61F 2002/30906 : shot- sand- or grit-blasted
• CPC Class Codes: A61F 2002/30915 : made of a stack of bonded perforated sheets, grids or wire meshes
• CPC Class Codes: A61F 2002/3092 : having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30925 : etched
• CPC Class Codes: A61F 2002/30929 : having at least two superposed coatings
• CPC Class Codes: A61F 2002/30934 : Special articulating surfaces
• CPC Class Codes: A61F 2002/30952 : using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/30955 : using finite-element analysis
• CPC Class Codes: A61F 2002/30957 : using a positive or a negative model, e.g. moulds
• CPC Class Codes: A61F 2002/30967 : Diffusion bonding
• CPC Class Codes: A61F 2002/30971 : Laminates, i.e. layered products
• CPC Class Codes: A61F 2002/342 : the outer shell having circumferential protrusions parallel to the equatorial plane, e.g. circumferential fins or wings
• CPC Class Codes: A61F 2002/3611 : Heads or epiphyseal parts of femur
• CPC Class Codes: A61F 2002/4018 : Heads or epiphyseal parts of humerus
• CPC Class Codes: A61F 2002/448 : comprising multiple adjacent spinal implants within the same intervertebral space or within the same vertebra, e.g. comprising two adjacent spinal implants
• CPC Class Codes: A61F 2210/0004 : bioabsorbable
• CPC Class Codes: A61F 2220/0058 : soldered or brazed or welded
• CPC Class Codes: A61F 2230/0006 : circular
• CPC Class Codes: A61F 2230/0008 : elliptical or oval
• CPC Class Codes: A61F 2230/001 : Figure-8-shaped, e.g. hourglass-shaped
• CPC Class Codes: A61F 2230/0017 : Angular shapes
• CPC Class Codes: A61F 2230/0019 : rectangular
• CPC Class Codes: A61F 2230/0021 : square
• CPC Class Codes: A61F 2230/0063 : Three-dimensional shapes
• CPC Class Codes: A61F 2230/0069 : cylindrical
• CPC Class Codes: A61F 2230/0082 : parallelepipedal
• CPC Class Codes: A61F 2230/0091 : helically-coiled or spirally-coiled, i.e. having a 2-D spiral cross-section
• CPC Class Codes: A61F 2230/0093 : Umbrella-shaped, e.g. mushroom-shaped
• CPC Class Codes: A61F 2250/0014 : having different values of a given property or geometrical feature, e.g. mechanical property or material property, at different locations within the same prosthesis
• CPC Class Codes: A61F 2250/0018 : differing in elasticity, stiffness or compressibility
• CPC Class Codes: A61F 2250/0023 : differing in porosity
• CPC Class Codes: A61F 2250/0024 : made from both porous and non-porous parts, e.g. adjacent parts
• CPC Class Codes: A61F 2250/0028 : differing in fibre orientations
• CPC Class Codes: A61F 2250/0089 : coded with symbols, e.g. dots, numbers, letters, words
• 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 2310/00047 : Aluminium or Al-based alloys
• CPC Class Codes: A61F 2310/00059 : Chromium or Cr-based alloys
• CPC Class Codes: A61F 2310/00089 : Zirconium or Zr-based alloys
• CPC Class Codes: A61F 2310/00095 : Niobium or Nb-based alloys
• CPC Class Codes: A61F 2310/00125 : Hafnium or Hf-based alloys
• CPC Class Codes: A61F 2310/00131 : Tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00149 : Platinum or Pt-based alloys
• CPC Class Codes: A61F 2310/00155 : Gold or Au-based alloys
• CPC Class Codes: A61F 2310/00179 : Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00293 : containing a phosphorus-containing compound, e.g. apatite
• CPC Class Codes: A61F 2310/00329 : Glasses, e.g. bioglass
• 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 2310/00634 : Coating made of zirconium oxide or hydroxides
• CPC Class Codes: A61F 2310/0073 : Coating or prosthesis-covering structure made of compounds based on metal carbides
• CPC Class Codes: A61L 27/04 : Metals or alloys
• CPC Class Codes: A61L 27/56 : Porous materials, e.g. foams or sponges
• CPC Class Codes: Y10T 428/1234 : Honeycomb, or with grain orientation or elongated elements in defined angular relationship in respective components [e.g., parallel, inter- secting, etc.]
• CPC Class Codes: Y10T 428/24273 : including aperture
• CPC Class Codes: Y10T 428/24298 : Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
• CPC Class Codes: Y10T 428/24322 : Composite web or sheet
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249961 : With gradual property change within a component

Abstract

A porous structure having a plurality of bonded sheets each sheet having at least one aperture that partially overlaps an aperture of at least one other sheet. A method of producing a porous structure including stacking a plurality of sheets each sheet having a multiplicity of apertures, and bonding each sheet to its adjoining sheet. An open-pore network structure having a multiplicity of sheets each having a repeatable pattern. At least a portion of each sheet is bonded to the web of an adjacent sheet. The porous area of at least one of the sheets is askew to the porous area of at least another of the sheets. An open-pore structure having a multiplicity of bonded sheets, each sheet having a repeatable pattern defining a multiplicity of perforations, and a plurality of apertures defined by the repeatable pattern, the apertures extending through the perforations of at least two adjacent plates.

Claims

1. A medically implantable porous structure comprising:

a plurality of stacked bonded sheets, each sheet having

a network of webs that define a multiplicity of apertures; and

at least one solid region integral with and surrounded by the network of webs;

wherein at least one solid region of at least one of the stacked bonded sheets is aligned with at least one of the solid regions of at least one adjacent sheet to form at least one integral structural element; and

wherein the solid regions are configured to form a transition from a foam-like structure to a stiffening member.

2. The medically implantable porous structure of claim 1 wherein the transition is taken from the group consisting of abrupt and gradual.

3. A medically implantable porous structure comprising:

a plurality of stacked bonded sheets, each sheet having

a network of webs that define a multiplicity of apertures; and

at least one solid region integral with and surrounded by the network of webs;

wherein at least one solid region of at least one of the stacked bonded sheets is aligned with at least one of the solid regions of at least one adjacent sheet to form at least one integral structural element; and

wherein the solid regions are configured to form at least one solid pillar.

4. A medically implantable porous structure comprising:

a plurality of stacked bonded sheets, each sheet having

a network of webs that define a multiplicity of apertures; and

at least one solid region integral with and surrounded by the network of webs;

wherein at least one solid region of at least one of the stacked bonded sheets is aligned with at least one of the solid regions of at least one adjacent sheet to form at least one integral structural element; and

wherein the integral structure element is configured to form solid pillars that extend throughout the medically implantable porous structure.

5. The medically implantable porous structure of claim 4 wherein the solid pillars protrude through the medically implantable porous structure.

6. A medically implantable porous structure comprising:

a plurality of stacked bonded sheets, each sheet having

a network of webs that define a multiplicity of apertures; and

at least one solid region integral with and surrounded by the network of webs;

wherein at least one solid region of at least one of the stacked bonded sheets is aligned with at least one of the solid regions of at least one adjacent sheet to form at least one integral structural element; and

wherein the apertures comprise;

a plurality of first apertures with a full penetration depth and

a plurality of second apertures with a partial penetration depth.

7. A medically implantable porous structure comprising:

a plurality of stacked bonded sheets, each sheet having

a network of webs that define a multiplicity of apertures; and

at least one solid region integral with and surrounded by the network of webs;

wherein at least one solid region of at least one of the stacked bonded sheets is aligned with at least one of the solid regions of at least one adjacent sheet to form at least one integral structural element; and

wherein the apertures have a dimension in the plane of the sheet of between 10 microns and 5000 microns.

8. A medically implantable porous structure comprising:

a plurality of stacked bonded sheets, each sheet having

a network of webs that define a multiplicity of apertures; and

at least one solid region integral with and surrounded by the network of webs;

wherein at least one solid region of at least one of the stacked bonded sheets is aligned with at least one of the solid regions of at least one adjacent sheet to form at least one integral structural element; and

the medically implantable porous structure has a porosity of between 5 percent and 90 percent by volume.

9. A medically implantable porous structure comprising:

a plurality of stacked bonded sheets, each sheet having;

a plurality of first apertures with a full penetration depth and

a plurality of second apertures with a partial penetration depth

the first apertures and second apertures having a diameter between 10 microns and 5000 microns.

wherein at least one of the first apertures in each of at least two adjacent sheets are aligned to form a tortuous pore.