CA2572699A1 - 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
CA2572699A1
CA2572699A1 CA002572699A CA2572699A CA2572699A1 CA 2572699 A1 CA2572699 A1 CA 2572699A1 CA 002572699 A CA002572699 A CA 002572699A CA 2572699 A CA2572699 A CA 2572699A CA 2572699 A1 CA2572699 A1 CA 2572699A1
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CA
Canada
Prior art keywords
coating
thickness
substrate
bearing portion
spraying
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
CA002572699A
Other languages
French (fr)
Other versions
CA2572699C (en
Inventor
Daniel Lawrynowicz
Aiguo Wang
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 CA2572699A1 publication Critical patent/CA2572699A1/en
Application granted granted Critical
Publication of CA2572699C publication Critical patent/CA2572699C/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
    • A61L27/02—Inorganic materials
    • A61L27/04—Metals or alloys
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
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    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
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    • A61F2/30767—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
    • A—HUMAN NECESSITIES
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/115—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by spraying molten metal, i.e. spray sintering, spray casting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • 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
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    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
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    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
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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 (44)

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 vacuum sintering 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 vacuum sintering 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 tot the vacuum sintering 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. The method according to claim 1, wherein the coating of the second material has a thickness of at least approximately 25 microns.
18. The method according to claim 1, wherein the first material is the same as the second material.
19. The method according to claim 1, wherein the medical implant component is a femoral ball head component.
20. The method according to claim 10, wherein the third thickness of the coating has a value of at least approximately 25 microns.
21. The method according to claim 10, wherein the first material is the same as the second material.
22. The method according to claim 10, wherein the medical implant component is a femoral ball head component.
23. 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 controlled atmospheric sintering process, wherein, upon completion of the fabrication, the the bearing portion is a bearing surface which is operable to articulate with a portion of a member or another medical implant component.
24. The method according to claim 23, wherein the first material is different from the second material.
25. The method according to claim 24, wherein said predetermined spraying technique is a thermal type spraying process.
26. The method according to claim 25, wherein said thermal type spraying technique is one of a plasma spraying process or a high velocity oxygen fuel (HVOF) spraying process.
27. The method according to claim 26, wherein the HVOF
spraying process is a kerosene type spraying process.
28. The method according to claim 24, wherein the first material is a biocompatible metal or an alloy thereof.
29. The method according to claim 28, wherein the second material is a ceramic material or a ceramic metal (cermet) composite material.
30. The method according to claim 29, 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.
31. 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 after the coating has been ground to the second thickness to a controlled atmospheric sintering process, 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.
32. The method according to claim 31, further comprising the step of grinding the coating of the second material after being subjected to the controlled atmospheric sintering process so that the coating has a third thickness which is less than the second thickness.
33. The method according to claim 32, wherein the first material is different from the second material.
34. The method according to claim 33, wherein said predetermined spraying technique is a thermal type spraying process.
35. The method according to claim 34, wherein said thermal type spraying technique is a plasma spraying process or a high velocity oxygen fuel (HVOF) spraying process.
36. The method according to claim 33, wherein the first material is a biocompatible metal or an alloy thereof.
37. The method according to claim 36, wherein the second material is a ceramic material.
38. The method according to claim 37, wherein the ceramic material is chromium oxide or chromium carbide.
39. The method according to claim 23, wherein the coating of the second material has a thickness of at least approximately 25 microns.
40. The method according to claim 23, wherein the first material is the same as the second material.
41. The method according to claim 23, wherein the medical implant component is a femoral ball head component.
42. The method according to claim 31, wherein the third thickness of the coating has a value of at least approximately 25 microns.
43. The method according to claim 31, wherein the first material is the same as the second material.
44. The method according to claim 31 wherein the medical implant component is a femoral ball head component.
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CA2572699C (en) 2012-10-23
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US8187660B2 (en) 2012-05-29
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