CA2548441A1 - Laser based metal deposition of implant structures - Google Patents

Laser based metal deposition of implant structures Download PDF

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Publication number
CA2548441A1
CA2548441A1 CA002548441A CA2548441A CA2548441A1 CA 2548441 A1 CA2548441 A1 CA 2548441A1 CA 002548441 A CA002548441 A CA 002548441A CA 2548441 A CA2548441 A CA 2548441A CA 2548441 A1 CA2548441 A1 CA 2548441A1
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CA
Canada
Prior art keywords
barrier layer
layer
bearing material
lbmd
porous
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
CA002548441A
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French (fr)
Other versions
CA2548441C (en
Inventor
Daniel F. Justin
Brent E. Stucker
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.)
MedicineLodge Inc
Original Assignee
Medicinelodge, Inc.
Daniel F. Justin
Brent E. Stucker
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Publication of CA2548441A1 publication Critical patent/CA2548441A1/en
Application granted granted Critical
Publication of CA2548441C publication Critical patent/CA2548441C/en
Expired - Fee Related legal-status Critical Current
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C8/00—Means to be fixed to the jaw-bone for consolidating natural teeth or for fixing dental prostheses thereon; Dental implants; Implanting tools
    • A61C8/0012—Means to be fixed to the jaw-bone for consolidating natural teeth or for fixing dental prostheses thereon; Dental implants; Implanting tools characterised by the material or composition, e.g. ceramics, surface layer, metal alloy
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • 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
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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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    • A61F2/36—Femoral heads ; Femoral endoprostheses
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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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    • 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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    • 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
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    • Y10T428/12826—Group VIB metal-base component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771—Transition metal-base component
    • Y10T428/12806—Refractory [Group IVB, VB, or VIB] metal-base component
    • Y10T428/12826—Group VIB metal-base component
    • Y10T428/12847—Cr-base component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771—Transition metal-base component
    • Y10T428/12861—Group VIII or IB metal-base component
    • Y10T428/12931—Co-, Fe-, or Ni-base components, alternative to each other

Abstract

A method of depositing a hard wear resistant surface onto a porous or non-porous base material of a medical implant. The medical implant device formed by a Laser Based Metal Deposition (LBMD) method. The porous material of the base promotes bone ingrowth allowing the implant to fuse strongly with the bone of a host patient. The hard wear resistant surface provides device longevity when applied to bearing surfaces such as artificial joint bearing surface or a dental implant bearing surface.

Claims (32)

1. A method for constructing a medical implant device, comprising:
forming a porous metal base;
depositing a corrosion barrier layer on said porous metal base, said deposition including laser based metal deposition (LBMD); and depositing a layer comprising a bearing material onto said corrosion barrier layer using LBMD.
2. A method as in claim 1, wherein said porous metal base comprises a material selected from the group consisting of cobalt-chrome, tantalum (Ta), titanium, stainless steel, and alloys thereof.
3. A method as in claim 1, wherein said corrosion barrier layer comprises titanium (Ti).
4. A method as in claim 1, wherein said corrosion barrier layer comprise an alloy including Ti.
5. A method as in claim 1, wherein said laser based metal deposition of said barrier layer includes applying said barrier layer as a foil and heating said foil with a laser.
6. A method as in claim 1, wherein said laser based metal deposition of said barrier layer includes applying said barrier layer as a powder and heating said powder with a laser.
7. A method as in claim 1, wherein said laser based metal deposition of said barrier layer includes applying said barrier layer as a wire.
8. A method as in claim 1 wherein said bearing material layer comprises of a Co-Cr layer comprising an alloy comprised of cobalt (Co) and chromium (Cr).
9. A method as in clam 8, wherein said alloy comprised of cobalt (Co) and chromium (Cr) is formed as a foil and heating said foil with a laser.
10. A method as in clam 8, wherein said alloy comprised of cobalt (Co) and chromium (Cr) is formed as a powder and heating said wire with a laser.
11. A method as in clam 8, wherein said alloy comprised of cobalt (Co) and chromium (Cr) is formed as a wire and heating said wire with a laser.
12. A method as in claim 8, wherein said laser based metal deposition of said corrosion barrier layer and said Co-Cr layer includes heating said corrosion barrier layer and said Co-Cr layer with a high power Nd YAG
laser.
13. A method as in claim 8, wherein said (LBMD) heats said Co-Cr sufficiently to melt said Co-Cr and also allows said Co-Cr to cool sufficiently quickly to form a small grain structure in said Co-Cr thereby hardening said Co-Cr.
14. A method as in claim 8, wherein said (LBMD) heats said Co-Cr sufficiently to melt said Co-Cr and also allows said Co-Cr to cool sufficiently quickly to form carbon interspersions in said Co-Cr, thereby hardening said Co-Cr.
15. A method as in clam 1, wherein said base comprises Ti-6Al-4V.
16. A method as in claim 1, wherein said base comprises Ti or any alloy thereof.
17. A method as in claim 1, wherein at least one of said corrosion barrier layer and said bearing material is deposited in a plurality of layers having differing material properties to form a gradient of material properties.
18. A method for constructing a medical implant device, comprising:
forming a first structure including a porous base;
depositing a corrosion barrier layer on said porous metal base, said deposition including laser based metal deposition; depositing a layer comprising Co and Cr (Co-Cr) onto said corrosion barrier layerusing laser based metal deposition; providing a second structure comprising Co-Cr;
and bonding said deposited Co-Cr portion of said first structure onto said second structure.
19. A method as in claim 18, wherein said porous base comprises Ti or alloy thereof.
20. A method as in claim 18, wherein said porous base comprises Co-Cr or any alloy thereof.
21. A method as in claim 18, wherein said porous base comprises tantalum or any alloy thereof.
22. A medical implant device, comprising:
a porous metal base; corrosion barrier layer formed on said porous metal base by laser based metal deposition (LBMD); and a second layer formed on said corrosion barrier layer using LBMD, the second layer having a hardness greater than the porous metal base.
23. A device as in claim 22, wherein said porous metal base comprises a material selected from the group consisting of Ta, Ti, stainless steel, and alloys thereof.
24. A device as in claim 22, wherein said corrosion barrier layer comprises Ti or alloys thereof.
25. A device as in claim 22, wherein said second layer comprises Co and Cr.
26. A device as in claim 22, wherein said porous metal base comprises Ta, said corrosion barrier layer comprises Ti or alloys thereof, and said second layer comprises Co and Cr.
27. A device as in claim 22, wherein said second layer is coupled to a second medical implant device.
28. A method for constructing a medical implant device, comprising:
forming a structure from a base metal;
depositing a second layer onto the surface of the base metal comprising a Co-Cr alloy bearing material using Laser Based Metal Deposition (LBMD).
29. A method as in claim 28, wherein said (LBMD) heats said Co-Cr bearing material sufficiently to melt said Co-Cr bearing material and also allows said Co-Cr bearing material to cool sufficiently quickly to form a small grain structure in said Co-Cr bearing material thereby hardening said Co-Cr bearing material.
30. A method as in claim 28, wherein said (LBMD) heats said Co-Cr sufficiently to melt said Co-Cr bearing material and also allows said Co-Cr bearing material to cool sufficiently quickly to form carbon interspersions in said Co-Cr bearing material, thereby hardening said Co-Cr bearing material.
medical implant device, comprising:a metal base structure;
second layer formed onto said metal base structure by Laser Based Metal Deposition (LBMD); the second layer comprising a Cobalt-Chrome based alloy having a hardness greater than the metal base structure.
31. A device as in claim 31, wherein said metal base structure comprises a material selected from the group consisting of Cobalt-Chrome, Tantalum, Titanium, Platinum, stainless steel, and alloys thereof.
32. A device as in claim 31, wherein said second layer is coupled to a second medical implant device.
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US10/811,038 US7001672B2 (en) 2003-12-03 2004-03-26 Laser based metal deposition of implant structures
PCT/US2004/040008 WO2005102684A1 (en) 2004-03-26 2004-11-30 Laser based metal deposition of implant structures

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US7001672B2 (en) 2006-02-21
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