CA2572598A1 - Method for fabricating a medical implant component and such component - Google Patents

Method for fabricating a medical implant component and such component Download PDF

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Publication number
CA2572598A1
CA2572598A1 CA002572598A CA2572598A CA2572598A1 CA 2572598 A1 CA2572598 A1 CA 2572598A1 CA 002572598 A CA002572598 A CA 002572598A CA 2572598 A CA2572598 A CA 2572598A CA 2572598 A1 CA2572598 A1 CA 2572598A1
Authority
CA
Canada
Prior art keywords
medical implant
implant component
coating
alloy
substrate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002572598A
Other languages
French (fr)
Other versions
CA2572598C (en
Inventor
Aiguo Wang
Daniel Lawrynowicz
Zongtao Zhang
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Howmedica Osteonics Corp
Original Assignee
Howmedica Osteonics Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Howmedica Osteonics Corp filed Critical Howmedica Osteonics Corp
Publication of CA2572598A1 publication Critical patent/CA2572598A1/en
Application granted granted Critical
Publication of CA2572598C publication Critical patent/CA2572598C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/28—Materials for coating prostheses
    • A61L27/30—Inorganic materials
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/02—Inorganic materials
    • A61L27/04—Metals or alloys
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/04—Impact or kinetic deposition of particles
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/129—Flame spraying
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment

Abstract

A method of fabricating a medical implant component. The method may include the steps of producing a substrate from a first material wherein the substrate has a bearing portion, spraying particles of a second material onto the bearing portion in accordance with a predetermined spraying technique to provide a coating thereon, and subjecting the coated bearing portion to a hot isostatic pressing process, a vacuum sintering process, or a controlled atmospheric sintering process. The first material may be the same as or different from the second material. The predetermined spraying technique may be a thermal type spraying process such as a plasma spraying process or a high velocity oxygen fuel spraying process.

Claims (30)

1. A method of fabricating a medical implant component, said method comprising the steps of:

producing a substrate from a first material, said substrate having a bearing portion;

spraying particles of a second material onto the bearing portion of the substrate in accordance with a predetermined spraying technique to provide a coating thereon; and subjecting the coated bearing portion to a hot isostatic pressing process, wherein, upon completion of the fabrication, the bearing portion is a bearing surface which is operable to articulate with a portion of a member or another medical implant component.
2. The method according to claim 1, wherein the first material is different from the second material.
3. The method according to claim 2, wherein said predetermined spraying technique is a thermal type spraying process.
4. The method according to claim 3, wherein said thermal type spraying technique is one of a plasma spraying process or a high velocity oxygen fuel (HVOF) spraying process.
5. The method according to claim 4, wherein the HVOF
spraying process is a kerosene type spraying process.
6. The method according to claim 2, wherein the first material is a biocompatible metal or an alloy thereof.
7. The method according to claim 6, wherein the second material is a ceramic material or a ceramic metal (cermet) composite material.
8. The method according to claim 7, wherein the ceramic material is any one of an oxide, carbide, nitride, or nitro-carbide of any of the following elements: silicon (Si), titanium (Ti), tantalum (Ta), tungsten (W), zirconium (Zr), niobium (Nb), chromium (Cr), or aluminium (Al); and wherein the cermet composite material is formed from any (i) oxide, carbide, nitride, or nitro-carbide of any of the following elements: Si, Ti, Ta, W, Zr, Nb, Cr, or Al, and (ii) any of Ti or an alloy thereof, cobalt chrome or an alloy thereof, Zr metal or an alloy thereof, Ta or an alloy thereof, or stainless steel.
9. A method of fabricating a medical implant component, said method comprising the steps of:

producing a substrate from a first material, said substrate having a bearing portion;

spraying particles of a second material onto the bearing portion of the substrate in accordance with a predetermined spraying technique to provide a coating of the second material thereon having a first thickness;

grinding the coating of the second material so that the coating has a second thickness which is less than the first thickness; and subjecting the coating of the second material to a hot isostatic pressing process after the coating has been ground to the second thickness, wherein, upon completion of the fabrication, the bearing portion of said substrate having the coating of the second material is operable to articulate with a portion of a member or another medical implant component.
10. The method according to claim 9, further comprising the step of grinding the coating of the second material after being subjected to the hot isostatic pressing process so that the coating has a third thickness which is less than the second thickness.
11. The method according to claim 10, wherein the first material is different from the second material.
12. The method according to claim 11, wherein said predetermined spraying technique is a thermal type spraying process.
13. The method according to claim 12, wherein said thermal type spraying technique is a plasma spraying process or a high velocity oxygen fuel (HVOF) spraying process.
14. The method according to claim 11, wherein the first material is a biocompatible metal or an alloy thereof.
15. The method according to claim 14, wherein the second material is a ceramic material.
16. The method according to claim 15, wherein the ceramic material is chromium oxide or chromium carbide.
17. A medical implant component comprising a substrate fabricated from a first material and including a bearing portion having a coating of a second material thereon so as to form a bearing surface, said coating of the second material having a thickness of at least approximately 25 microns, in which an interface between the substrate and the coating is an inter-diffusion zone of the first material and the second material.
18. The medical implant component according to claim 17 wherein the first material is the same as the second material.
19. The medical implant component according to claim 17, wherein the first material is different from the second material.
20. The medical implant component according to claim 19, wherein the first material is a biocompatible metal or an alloy thereof.
21. The medical implant component according to claim 20, wherein the second material is a ceramic material or a ceramic metal (cermet) composite material.
22. The medical implant component according to claim 21, wherein the ceramic material is any one of an oxide, carbide, nitride, or nitro-carbide of any of the following elements:
silicon (Si), titanium (Ti), tantalum (Ta), tungsten (W), zirconium (Zr), niobium (Nb), chromium (Cr), or aluminium (Al); and wherein the cermet composite material is formed from any (i) oxide, carbide, nitride, or nitro-carbide of any of the following elements: Si, Ti, Ta, W, Zr, Nb, Cr, or Al, and (ii) any of Ti or an alloy thereof, cobalt chrome or an alloy thereof, Zr metal or an alloy thereof, Ta or an alloy thereof, or stainless steel.
23. The medical implant component according to claim 17, wherein the medical implant component is a femoral ball head component.
24. The method according to claim 1, wherein the coating of the second material has a thickness of at least approximately
25 microns.

25. The method according to claim 1, wherein the first material is the same as the second material.
26. The method according to claim 1, wherein the medical implant component is a femoral ball head component.
27. The method according to claim 10, wherein the third thickness of the coating has a value of at least approximately 25 microns.
28. The method according to claim 10, wherein the first material is the same as the second material.
29. The method according to claim 10, wherein the medical implant component is a femoral ball head component.
30. The medical implant component according to claim 17, wherein the bearing surface is operable to articulate with a portion of a member or another medical implant component.
CA2572598A 2006-01-05 2006-12-29 Method for fabricating a medical implant component and such component Expired - Fee Related CA2572598C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US11/325,791 US20070158446A1 (en) 2006-01-05 2006-01-05 Method for fabricating a medical implant component and such component
US11/325,791 2006-01-05

Publications (2)

Publication Number Publication Date
CA2572598A1 true CA2572598A1 (en) 2007-07-05
CA2572598C CA2572598C (en) 2010-12-07

Family

ID=38080966

Family Applications (1)

Application Number Title Priority Date Filing Date
CA2572598A Expired - Fee Related CA2572598C (en) 2006-01-05 2006-12-29 Method for fabricating a medical implant component and such component

Country Status (7)

Country Link
US (1) US20070158446A1 (en)
EP (1) EP1808186B1 (en)
JP (1) JP2007229445A (en)
AT (1) ATE478693T1 (en)
AU (1) AU2007200033B2 (en)
CA (1) CA2572598C (en)
DE (1) DE602007008622D1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021205232A1 (en) * 2020-04-06 2021-10-14 Burrell Robert E Process for making antiinflammatory, antibacterial, antifungal and viricidal materials

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ATE528023T1 (en) 2008-12-30 2011-10-15 Sandvik Intellectual Property DESIGNED SURFACES FOR USE IN MEDICAL IMPLANTS OR INSTRUMENTS

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Also Published As

Publication number Publication date
AU2007200033A1 (en) 2007-07-19
ATE478693T1 (en) 2010-09-15
CA2572598C (en) 2010-12-07
AU2007200033B2 (en) 2011-11-24
EP1808186A3 (en) 2007-10-10
JP2007229445A (en) 2007-09-13
US20070158446A1 (en) 2007-07-12
EP1808186B1 (en) 2010-08-25
EP1808186A2 (en) 2007-07-18
DE602007008622D1 (en) 2010-10-07

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