Sintered coatings for implantable prostheses

• US 8,066,770 B2
• Filed: 12/20/2007
• Issued: 11/29/2011
• Est. Priority Date: 05/31/2007
• Status: Active Grant

• Current Assignee: Depuy Products Incorporated (Johnson & Johnson)
• Original Assignee: Depuy Products Incorporated (Johnson & Johnson)
• Inventors: Aboud, Bernice, Rivard, Kori
• Primary Examiner(s): Stewart; Alvin J
• Application Number:
  US11/961,382
• Publication Number:
  US 20080300682A1
• Time in Patent Office: 1,440 Days
• Field of Search: 623/16.11, 623/20.17, 623/22.33, 623/23.29, 623/23.5, 623/23.52, 623/23.53, 623/23.54, 623/23.55, 623/23.6, 623/23.72, 623/23.73, 623/23.74, 623/23.76
• US Class Current: 623/16.11
• 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 2/36 Femoral heads ; Femoral endoprostheses
• CPC Class Codes: A61F 2/3662 Femoral shafts
• CPC Class Codes: A61F 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/30929 having at least two superposed coatings
• CPC Class Codes: A61F 2002/30968 Sintering
• CPC Class Codes: A61F 2002/3631 with an integral complete or partial peripheral collar or bearing shoulder at its base
• CPC Class Codes: A61F 2250/0023 differing in porosity
• 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 2310/00131 Tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00407 Coating made of titanium or of Ti-based alloys
• CPC Class Codes: A61F 2310/00413 Coating made of cobalt or of Co-based alloys
• CPC Class Codes: A61F 2310/00449 Coating made of chromium or Cr-based alloys
• CPC Class Codes: A61F 2310/00497 Coating made of molybdenum or Mo-based alloys
• CPC Class Codes: A61F 2310/00544 Coating made of tantalum or Ta-based alloys
• 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: B22F 1/06 : Metallic powder characterised by the shape of the particles nanosized particles B22F1/054
• CPC Class Codes: B22F 1/065 : Spherical particles
• CPC Class Codes: B22F 2998/00 : Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 7/004 : comprising at least one non-porous part
• CPC Class Codes: C23C 24/08 : by application of heat or pressure and heat C23C24/04 takes precedence

Abstract

The present invention concerns articles having an outer surface that bears at least two layers of metal particles, wherein the at least two layers comprise an outermost layer and an intermediate layer; the outermost layer consisting essentially of aspherical metallic particles having a mean particle size of 50 to 500 microns; and the intermediate layer consisting essentially of substantially spherical metallic particles having a mean particle size of from 50 to 500 microns. In some embodiments, the outer surface has a volume porosity of between about 20% to about 80%.

Claims

1. A prosthesis having an outer surface that bears at least two layers of metal particles, wherein:

one of said at least two layers is an outermost layer consisting essentially of substantially aspherical metallic particles having irregular cross-sections and a mean particle size of 50 to 500 microns; and

at least one of said at least two layers is an intermediate layer that is disposed between said outermost layer and said outer surface and consists essentially of substantially spherical metallic particles having a mean particle size of 50 to 500 microns.

2. The prosthesis of claim 1, wherein the spherical metallic particles have a mean particle size of 150-300 microns.

3. The prosthesis of claim 1, wherein the aspherical metallic particles have a mean particle size of 150-300 microns.

4. The prosthesis of claim 1, wherein said aspherical metallic particles comprise one or more of cobalt, chromium, molybdenum, tantalum, and titanium.

5. The prosthesis of claim 1, wherein said spherical metallic particles comprise one or more of cobalt, chromium, molybdenum, tantalum, and titanium.

6. The prosthesis of claim 1, wherein said surface, said spherical metallic particles and said aspherical metallic particles comprise titanium.

7. The prosthesis of claim 1, wherein said surface, said spherical metallic particles and said aspherical metallic particles comprise cobalt and chromium.

8. The prosthesis of claim 1, wherein said surface, said spherical metallic particles and said aspherical metallic particles comprise tantalum.

9. The prosthesis of claim 1, wherein the layers of spherical metallic particles and aspherical metallic particles have a combined thickness of 100 microns to 2.5 mm.

10. The prosthesis of claim 1, wherein the outer surface has a volume porosity of between about 20% to about 80%.

11. An article having an outer surface that bears at least two layers of metal particles, wherein:

said at least two layers comprise an outermost layer and an intermediate layer;

said outermost layer consisting essentially of aspherical metallic particles having irregular cross-sections and a mean particle size of 50 to 500 microns; and

said intermediate layer consisting essentially of substantially spherical metallic particles having a mean particle size of from 50 to 500 microns.

12. The article of claim 11, wherein the spherical metallic particles have a mean particle size of 150-300 microns and the aspherical metallic particles have a mean particle size of 150-300 microns.

13. The article of claim 11, wherein said aspherical metallic particles and the spherical metallic particles each comprise one or more of cobalt, chromium, molybdenum, tantalum, and titanium.

14. The article of claim 11, wherein said substrate, said spherical metallic particles and said aspherical metallic particles comprise titanium.

15. The article of claim 11, wherein said substrate, said spherical metallic particles and said aspherical metallic particles comprise cobalt and chromium.

16. The article of claim 11, wherein said substrate, said spherical metallic particles and said aspherical metallic particles comprise tantalum.

17. The article of claim 11, wherein the layers of spherical metallic particles and aspherical metallic particles have a combined thickness of 100 microns to 2.5 mm on said substrate.

18. The article of claim 11, wherein the outer surface has a volume porosity of between about 20% to about 80%.

19. A method comprising:

providing a substrate;

applying one or more coatings of substantially spherical metallic particles on said substrate, said spherical metallic particles having a mean particle size of from 50 to 500 microns;

applying one or more additional coatings on said spherical metallic particles, said additional coatings comprising aspherical metallic particles having irregular cross-sections and a mean particle size of 50 to 500 microns; and

metallurgically sintering said particles onto the substrate.

20. The method of claim 19, wherein the spherical metallic particles have a mean particle size of 150-300 microns and the aspherical metallic particles have a mean particle size of 150-300 microns.

21. The method of claim 19, wherein the aspherical metallic particles and the spherical metallic particles each comprise one or more of cobalt, chromium, molybdenum, tantalum, and titanium.

22. The method of claim 19, wherein the substrate, the spherical metallic particles and the aspherical metallic particles each comprise titanium.

23. The method of claim 19, wherein the substrate, the spherical metallic particles and the aspherical metallic particles each comprise cobalt and chromium.

24. The method of claim 19, wherein the substrate, the spherical metallic particles and the aspherical metallic particles each comprise tantalum.

25. The method of claim 19, wherein the layers of spherical metallic particles and aspherical metallic particles have a combined thickness of 100 microns to 2.5 mm.

26. In a method for implanting a prosthesis in a human or animal body in contact with bone, the improvement comprising at least a portion of the prosthesis in contact with said bone having a surface bearing at least two layers of metal particles, wherein:

said at least two layers comprise an outermost layer and an intermediate layer;

said outermost layer consisting essentially of aspherical metallic particles having irregular cross-sections and a mean particle size of 50 to 500 microns; and

said intermediate layer consisting essentially of substantially spherical metallic particles having a mean particle size of from 50 to 500 microns.

27. The method of claim 26, wherein the spherical metallic particles have a mean particle size of 150-300 microns and the aspherical metallic particles have a mean particle size of 150-300 microns.

28. The method of claim 26, wherein the aspherical metallic particles and the spherical metallic particles each comprise one or more of cobalt, chromium, molybdenum, tantalum, and titanium.