Oxidized zirconium on a porous structure for bone implant use

• US 7,648,735 B2
• Filed: 08/05/2005
• Issued: 01/19/2010
• Est. Priority Date: 12/16/2003
• Status: Expired due to Fees

• Current Assignee: Smith & Nephew Incorporated (Smith & Nephew PLC)
• Original Assignee: Smith & Nephew Incorporated (Smith & Nephew PLC)
• Inventors: Pawar, Vivek, Hunter, Gordon
• Primary Examiner(s): Barr; Michael
• Assistant Examiner(s): BOWMAN, ANDREW J
• Application Number:
  US11/198,446
• Publication Number:
  US 20060020346A1
• Time in Patent Office: 1,628 Days
• Field of Search: 623/16, 623/22.15, 623/23.5, 623/18.11, 623/20.14, 623/22, 623/23.34, 623/23.51, 623/22.21, 419/2, 427/248.1
• US Class Current: 427/248.1
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• 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 2/38 for elbows or knees
• CPC Class Codes: A61F 2/44 for the spine, e.g. vertebrae, spinal discs
• CPC Class Codes: A61F 2002/2835 Bone graft implants for filling a bony defect or an endoprosthesis cavity, e.g. by synthetic material or biological material
• CPC Class Codes: A61F 2002/30261 parallelepipedal
• CPC Class Codes: A61F 2002/3092 having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30967 Diffusion bonding
• CPC Class Codes: A61F 2002/30968 Sintering
• CPC Class Codes: A61F 2002/30971 Laminates, i.e. layered products
• CPC Class Codes: A61F 2230/0082 parallelepipedal
• CPC Class Codes: A61F 2310/00011 Metals or alloys
• CPC Class Codes: A61F 2310/00089 Zirconium or Zr-based alloys
• CPC Class Codes: A61F 2310/00161 Carbon; Graphite
• CPC Class Codes: A61F 2310/00173 Graphite
• CPC Class Codes: A61F 2310/00179 Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00634 Coating made of zirconium oxide or hydroxides
• CPC Class Codes: A61L 27/306 Other specific inorganic materials not covered by A61L27/303 - A61L27/32
• CPC Class Codes: A61L 27/56 : Porous materials, e.g. foams or sponges
• CPC Class Codes: B32B 15/04 : comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: C23C 4/00 : Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge build-up welding B23K, e.g. B23K5/18, B23K9/04
• CPC Class Codes: C23C 4/10 : Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/24996 : With internal element bridging layers, nonplanar interface between layers, or intermediate layer of commingled adjacent foam layers
• CPC Class Codes: Y10T 428/24997 : Of metal-containing material
• CPC Class Codes: Y10T 428/249975 : Void shape specified [e.g., crushed, flat, round, etc.]
• CPC Class Codes: Y10T 428/24999 : Inorganic
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

A composition, a medical implant constructed from the composition, and a method of making the composition are described. The composition is a composite material, comprising a porous, reticulated, open cell network having at least part of its surface coated with blue-black or black oxidized zirconium.

Claims

1. A method of making a composite material for medical implant use comprising the steps of:

providing a medical implant material having a reticulated open cell structure,

depositing a layer of zirconium or zirconium alloy onto said structure, wherein said zirconium or zirconium alloy has a zirconium content of from about 80 weight % to about 100 weight %; and

,

oxidizing said layer to blue-black or black oxidized zirconium.

2. The method of claim 1 wherein said step of depositing comprises chemical vapor deposition or physical vapor deposition or both.

3. The method of claim 1 wherein said step of oxidizing comprises oxidizing using air, steam, or water oxidation or any combination thereof.

4. The method of claim 1 wherein said step of oxidizing comprises oxidizing in a furnace having an oxygen-containing atmosphere.

5. The method of claim 1, wherein said step of depositing comprises electrochemical deposition.

6. The method of claim 2, wherein said step of depositing comprises chemical vapor deposition.

7. The method of claim 6, further comprising depositing a gaseous or liquid precursor containing zirconium.

8. The method of claim 7, wherein said precursor is an organometallic or an inorganic compound.

9. The method of claim 7, wherein said step of depositing comprises decomposing said precursor to form metallic zirconium on said substrate.

10. The method of claim 2, wherein said step of depositing comprises physical vapor deposition.

11. The method of claim 10, wherein said step of depositing comprises evaporation of zirconium alloy in vacuum and condensation of zirconium alloy vapors onto said substrate.

12. The method of claim 11, wherein said step of evaporation comprises heating the alloy, or sputtering the alloy with inert gases or arc discharge.

13. The method of claim 1, wherein said zirconium or zirconium alloy has a zirconium content of from about 95 weight % to about 100 weight %.

14. A method of making a composite material for medical implant use comprising the steps of:

providing a medical implant material having a reticulated open cell structure,

depositing by chemical vapor deposition a layer of zirconium or zirconium alloy onto said structure, wherein said zirconium or zirconium alloy has a zirconium content of from about 80 weight % to about 100 weight %; and

,

oxidizing said layer to blue-black or black oxidized zirconium by exposing said medical implant material having said deposited layer of zirconium or zirconium alloy to temperature of at least 700°

F. in an oxygen-containing atmosphere.