Medical implants having a porous coated surface
First Claim
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1. A method of making a medical implant having a porous surface and a blue, blue-black, or black oxidized zirconium, said method comprising:
- forming a medical implant from a zirconium or zirconium alloy material;
applying a HIP sintering material to at least one surface of said implant;
attaching an enclosure around a surface of said implant such that the attached enclosure contains said HIP sintering material, said enclosure having an inner surface which is proximal to said implant surface and an outer surface which is distal to said implant surface and wherein the enclosure is formed of a collapsible material;
evacuating substantially all air from said enclosure;
sealing the evacuated enclosure;
placing said implant, said HIP sintering material, and said enclosure in a HIP furnace;
pressurizing the inside of said HIP furnace to an elevated pressure in an atmosphere comprising an inert gas and oxygen, said step of pressurizing comprising pressurizing to a total pressure of from about 20 to about 4000 bar and a partial pressure of oxygen of from about 0.1 to about 21 mbar;
adjusting the temperature in said furnace to a temperature of from 500°
C. to 1000°
C.; and
,causing said implant, said HIP sintering material, and said enclosure in said HIP furnace to remain exposed to said temperatures and pressures for a time sufficient to fuse said HIP sintering material together and to said surface of said implant; and
oxidize at least a portion of the surface of said implant to blue, blue-black, or black oxidized zirconium, said time ranging from about 30 minutes to about 10 hours; and
thereafter,cooling said implant, said HIP sintering material, and said enclosure; and
,removing said enclosure.
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Abstract
A process for making a diffusion hardened medical implant having a porous surface is disclosed. The medical implant is made by a hot isostatic pressing process which simultaneously forms that porous surface and the diffusion hardened surface.
179 Citations
25 Claims
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1. A method of making a medical implant having a porous surface and a blue, blue-black, or black oxidized zirconium, said method comprising:
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forming a medical implant from a zirconium or zirconium alloy material; applying a HIP sintering material to at least one surface of said implant; attaching an enclosure around a surface of said implant such that the attached enclosure contains said HIP sintering material, said enclosure having an inner surface which is proximal to said implant surface and an outer surface which is distal to said implant surface and wherein the enclosure is formed of a collapsible material; evacuating substantially all air from said enclosure; sealing the evacuated enclosure; placing said implant, said HIP sintering material, and said enclosure in a HIP furnace; pressurizing the inside of said HIP furnace to an elevated pressure in an atmosphere comprising an inert gas and oxygen, said step of pressurizing comprising pressurizing to a total pressure of from about 20 to about 4000 bar and a partial pressure of oxygen of from about 0.1 to about 21 mbar; adjusting the temperature in said furnace to a temperature of from 500°
C. to 1000°
C.; and
,causing said implant, said HIP sintering material, and said enclosure in said HIP furnace to remain exposed to said temperatures and pressures for a time sufficient to fuse said HIP sintering material together and to said surface of said implant; and oxidize at least a portion of the surface of said implant to blue, blue-black, or black oxidized zirconium, said time ranging from about 30 minutes to about 10 hours; and
thereafter,cooling said implant, said HIP sintering material, and said enclosure; and
,removing said enclosure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A method of making a medical implant having a blue, blue-black, or black oxidized zirconium, said method comprising:
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forming a medical implant from a zirconium or zirconium alloy material; placing said implant in a HIP furnace; pressurizing the inside of said HIP furnace to an elevated pressure in an atmosphere comprising an inert gas and oxygen, said step of pressurizing comprising pressurizing to a total pressure of from about 20 to about 4000 bar and a partial pressure of oxygen of from about 0.1 to about 21 mbar; adjusting the temperature in said furnace to a temperature of from 500°
C. to 1000°
C.; and
,causing said implant to remain exposed to said temperatures and pressures for a time sufficient to oxidize at least a portion of the surface of said implant to blue, blue-black, or black oxidized zirconium, said time ranging from about 30 minutes to about 10 hours. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25)
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Specification