Use of CoCrMo to augment biocompatibility in polycrystalline diamond compacts

• US 7,396,505 B2
• Filed: 08/27/2004
• Issued: 07/08/2008
• Est. Priority Date: 08/12/1994
• Status: Expired due to Fees

• Current Assignee: Diamicron, Inc.
• Original Assignee: Diamicron, Inc.
• Inventors: Vail, Michael A., Pope, Bill J., Dixon, Richard H., Taylor, Jeffery K., Blackburn, Dean C., Medford, Troy, Gardinier, Clayton F., Pope, Louis M., Jensen, Kenneth M.
• Primary Examiner(s): King; Roy
• Assistant Examiner(s): MAI, NGOCLAN THI
• Application Number:
  US10/929,114
• Publication Number:
  US 20050158200A1
• Time in Patent Office: 1,411 Days
• Field of Search: 419/11, 419/9, 228/121, 228/121.1
• US Class Current: 419/9
• 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 2/32 for the hip
• CPC Class Codes: A61F 2/3662 Femoral shafts
• CPC Class Codes: A61F 2/3676 Distal or diaphyseal parts of shafts
• 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 2/4425 made of articulated components
• CPC Class Codes: A61F 2002/30092 using shape memory or superelastic materials, e.g. nitinol
• CPC Class Codes: A61F 2002/30331 made by longitudinally pushing a protrusion into a complementarily-shaped recess, e.g. held by friction fit
• CPC Class Codes: A61F 2002/30392 Rotation
• CPC Class Codes: A61F 2002/30398 Sliding
• CPC Class Codes: A61F 2002/30433 using additional screws, bolts, dowels, rivets or washers e.g. connecting screws
• CPC Class Codes: A61F 2002/30451 soldered or brazed or welded
• CPC Class Codes: A61F 2002/30578 having apertures, e.g. for receiving fixation screws
• CPC Class Codes: A61F 2002/30649 Ball-and-socket joints
• CPC Class Codes: A61F 2002/30836 knurled
• CPC Class Codes: A61F 2002/30841 Sharp anchoring protrusions for impaction into the bone, e.g. sharp pins, spikes
• CPC Class Codes: A61F 2002/3085 with a threaded, e.g. self-tapping, bone-engaging surface, e.g. external surface
• CPC Class Codes: A61F 2002/30884 Fins or wings, e.g. longitudinal wings for preventing rotation within the bone cavity
• CPC Class Codes: A61F 2002/30904 serrated profile, i.e. saw-toothed
• CPC Class Codes: A61F 2002/30934 : Special articulating surfaces
• CPC Class Codes: A61F 2002/30968 : Sintering
• CPC Class Codes: A61F 2002/3097 : using laser
• CPC Class Codes: A61F 2002/30971 : Laminates, i.e. layered products
• CPC Class Codes: A61F 2002/3611 : Heads or epiphyseal parts of femur
• CPC Class Codes: A61F 2002/3631 : with an integral complete or partial peripheral collar or bearing shoulder at its base
• CPC Class Codes: A61F 2002/443 : having two transversal endplates and at least one intermediate component
• CPC Class Codes: A61F 2002/4631 : the prosthesis being specially adapted for being cemented
• CPC Class Codes: A61F 2210/0014 : using shape memory or superelastic materials, e.g. nitinol
• CPC Class Codes: A61F 2220/0025 : Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: A61F 2220/0033 : made by longitudinally pushing a protrusion into a complementary-shaped recess, e.g. held by friction fit
• CPC Class Codes: A61F 2220/0041 : using additional screws, bolts, dowels or rivets, e.g. connecting screws
• CPC Class Codes: A61F 2220/0058 : soldered or brazed or welded
• 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 2310/00095 : Niobium or Nb-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 2310/00167 : Diamond or diamond-like carbon
• CPC Class Codes: A61F 2310/00269 : based on metal carbides
• CPC Class Codes: A61F 2310/00281 : containing silicon carbide
• CPC Class Codes: A61F 2310/00293 : containing a phosphorus-containing compound, e.g. apatite
• CPC Class Codes: A61F 2310/0058 : Coating made of diamond or of diamond-like carbon DLC
• CPC Class Codes: A61L 27/303 : Carbon
• CPC Class Codes: A61L 27/306 : Other specific inorganic materials not covered by A61L27/303 - A61L27/32
• CPC Class Codes: B22F 1/12 : Metallic powder containing non-metallic particles containing lubricating or binding agents or organic material B22F1/10
• CPC Class Codes: B22F 2003/247 : Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
• CPC Class Codes: B22F 2998/10 : Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/12 : Both compacting and sintering by forging B22F3/17
• CPC Class Codes: B22F 7/062 : involving the connection or repairing of preformed parts
• CPC Class Codes: B24B 9/162 : by bruting, i.e. rubbing two precious stones against each other
• CPC Class Codes: B29C 43/006 : Pressing and sintering powders, granules or fibres
• CPC Class Codes: B29C 43/16 : Forging
• CPC Class Codes: B29K 2503/04 : Inorganic materials
• CPC Class Codes: B29L 2031/7532 : Artificial members, protheses
• CPC Class Codes: C04B 2235/3839 : Refractory metal carbides
• CPC Class Codes: C04B 2235/3856 : Carbonitrides, e.g. titanium carbonitride, zirconium carbonitride
• CPC Class Codes: C04B 2235/3886 : Refractory metal nitrides, e.g. vanadium nitride, tungsten nitride
• CPC Class Codes: C04B 2235/427 : Diamond
• CPC Class Codes: C04B 2235/5436 : micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/5445 : submicron sized, i.e. from 0,1 to 1 micron
• CPC Class Codes: C04B 2235/5472 : Bimodal, multi-modal or multi-fraction
• CPC Class Codes: C04B 35/52 : based on carbon, e.g. graphite
• CPC Class Codes: C04B 35/634 : Polymers C04B35/636 takes precedence
• CPC Class Codes: C04B 35/645 : Pressure sintering
• CPC Class Codes: C22C 2026/006 : with additional metal compounds being carbides
• CPC Class Codes: C22C 2204/00 : End product comprising different layers, coatings or parts of cermet
• CPC Class Codes: C22C 26/00 : Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
• CPC Class Codes: C22C 29/067 : comprising a particular metallic binder

Abstract

CoCrMo can be used to enhance biocompatibility of a sintered polycrystalline diamond compact.

Claims

1. A method for improving the biocompatibility of polycrystalline diamond compacts comprising:

selecting a diamond feedstock comprising diamond particles,

selecting a solvent-catalyst metal,

said solvent-catalyst metal including CoCrMo alloy,

said CoCrMo alloy including Ni,

sintering said diamond into a sintered polycrystalline diamond compact in the presence of said solvent-catalyst metal such that said solvent-catalyst metal is present between the diamond particles in said compact;

wherein said sintered polycrystalline diamond compact has enhanced biocompatibility compared to a sintered polycrystalline diamond compact that lacks use of Co and Ni as a solvent-catalyst metal.

2. A method as recited in claim 1 wherein said polycrystalline diamond compact is substantially free of unbonded Co and Ni.

3. A method as recited in claim 1 wherein said compact includes interstitial carbides in said diamond table, said carbides being formed from said solvent-catalyst metal.

4. A method as recited in claim 1 wherein said solvent-catalyst metal includes a quantity of one or more of the following:

Ti and W.

5. A method as recited in claim 1 wherein said compact includes interstitial metal between the diamond particles in the compact, said interstitial metal including at least one of Co and Ni.

6. A method for improving the biocompatibility of polycrystalline diamond compacts comprising:

selecting a diamond feedstock comprising diamond particles,

selecting a substrate that includes a solvent-catalyst metal,

said solvent-catalyst metal including CoCrMo and Ni,

sintering said diamond and said substrate into a sintered polycrystalline diamond compact, said compact comprising a diamond table formed on the surface of said substrate,

said sintering causing a sweep of solvent-catalyst metal from said susbtrate to pass into said diamond feedstock, such that said diamond table comprises interstitial spaces between said diamond particles with solvent-catalyst metal therein, and such that said diamond table comprises both diamond to diamond and diamond to metal bonds;

wherein said sintered polycrystalline diamond compact has enhanced biocompatibility compared to a sintered polycrystalline diamond compact that does not utilize CoCrMo as a solvent-catalyst metal.

7. A method as recited in claim 6 wherein said polycrystalline diamond compact is substantially free of unbonded Co and Ni.

8. A method as recited in claim 6 wherein said diamond table comprises carbides formed from said solvent-catalyst metal.

9. A method as recited in claim 6 wherein said solvent-catalyst metal includes a quantity of one or more of the following:

Ti and W.