Bone implants and method of manufacture

• US 8,864,839 B2
• Filed: 01/09/2013
• Issued: 10/21/2014
• Est. Priority Date: 11/23/2011
• Status: Active Grant

• Current Assignee: BONE Pharm LLC
• Original Assignee: Vivex Biomedical, Inc. (Vivex Biologic, Inc.)
• Inventors: Ganey, Timothy
• Primary Examiner(s): STEWART, ALVIN J
• Application Number:
  US13/737,020
• Publication Number:
  US 20130131812A1
• Time in Patent Office: 650 Days
• Field of Search: 623 1611- 2353
• US Class Current: 623/23.53
• CPC Class Codes: A61B 17/7098 wherein the implant is permeable or has openings, e.g. fenestrated screw hollow surgical screws A61B17/864
• CPC Class Codes: A61B 17/80 Cortical plates , i.e. bone plates; Instruments for holding or positioning cortical plates, or for compressing bones attached to cortical plates
• 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 2/44 for the spine, e.g. vertebrae, spinal discs
• 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 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 2002/30062 (bio)absorbable, biodegradable, bioerodable, (bio)resorbable, resorptive
• 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 2002/30593 hollow
• CPC Class Codes: A61F 2002/30604 modular
• CPC Class Codes: A61F 2002/30838 Microstructures
• CPC Class Codes: A61F 2002/30904 serrated profile, i.e. saw-toothed
• 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 2002/3093 for promoting ingrowth of bone tissue
• CPC Class Codes: A61F 2002/3096 trimmed or cut to a customised size
• CPC Class Codes: A61F 2002/3097 using laser
• CPC Class Codes: A61F 2002/30971 Laminates, i.e. layered products
• 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 2310/00976 : 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: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: Y10T 29/49 : Method of mechanical manufacture
• CPC Class Codes: Y10T 29/49746 : by applying fluent material, e.g., coating, casting
• CPC Class Codes: Y10T 29/4998 : Combined manufacture including applying or shaping of fluent material

Abstract

An implant device for humans or mammals has a body structure having an exposed surface and one or more selected portions of the exposed surface having a bone formation enhancing 3-dimensional pattern. The exposed surface can be on exterior portions of the body structure or internal portions of the body structure or both. The one or more selected portions of the exposed portions having the bone formation enhancing 3-dimensional patterns are in the external exposed surfaces or in the internal exposed surfaces or both internal and external exposed surfaces.

Claims

1. An implant device for humans or mammals comprises:

a solid body structure having an exposed surface;

one or more selected portions of the exposed surface having a porosity created by bone formation enhancing repeatable geometric 3-dimensional pattern duplicating or replicating the cancellous morphology of under-modelled pre-cancellous bone mimicking a marine or sea mammal bone structure wherein the repeatable geometric 3-dimensional pattern is repeatably placed on portions of the exposed surface to create a substantially continuous network having voids having a medium width of 500 to 800 microns formed as a trabecular structure which enhances bone formation, the voids of the substantially continuous network extend to a depth of 150 microns or less from the one or more portions of the exposed selected surface having the 3-dimensional pattern providing the depth of the 3-dimensional pattern, the depth being the distance the pattern penetrates into the body structure to produce the repeatable 3-dimensional pattern for enhancing bone formation of about 150 microns or less.

2. The implant device for humans or mammals of claim 1 wherein the exposed surface is on exposed exterior portions of the body structure or exposed internal portions of the body structure or both.

3. The implant device for humans or mammals of claim 2 wherein the one or more selected portions of the exposed portions having the bone formation enhancing repeatable geometric 3-dimensional patterns are in the external exposed surfaces or in the internal exposed surfaces or both internal and external exposed surfaces.

4. The implant device for humans or mammals of claim 1 wherein the solid body structure is made of an implantable plastic or polymer.

5. The implant device for humans or mammals of claim 4 wherein the plastic is PEEK.

6. The implant device for humans or mammals of claim 1 wherein the solid body structure is made of a metal suitable for implanting in a human or mammal.

7. The implant device for humans or mammals of claim 6 wherein the metal is titanium or a titanium alloy.

8. The implant device for humans or mammals of claim 6 wherein the metal is stainless steel or a stainless steel alloy.

9. The implant device for humans or mammals of claim 1 wherein the plastic material can be any implantable grade material such as PEEK (polyether ether ketone), PEKK (polyether ketone ketone), polyethylene, ultra high molecular weight polyethylene, polyphenylsulfone, polysulfone, polythermide, acetal copolymer, polyester woven or solid or implantable grade lennite UHME-PE.

10. The implant device for humans or mammals of claim 1 may include anchoring holes to secure the device to the skeletal structure with fasteners or alternatively can simply be held in place by and between adjacent skeletal structures.

11. The implant device for humans or mammals of claim 1 wherein the sea or marine mammal is a whale.

12. The implant device for humans or mammals of claim 1 wherein the sea or marine mammal is a dolphin.

13. The implant device for humans or mammals of claim 1 wherein the bone formation enhancing repeatable geometric 3-dimensional pattern mimics or replicates the following characteristics of whale bone;

14. The implant device for humans or mammals of claim 1 wherein the implant at select portions exhibits a stress neutral isotropic structure for enhancing bone formation.