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US 4,542,539 AGranted
Surgical implant having a graded porous coating
AssigneeArtech
InventorsRussell H. Rowe, Jr., Paul J. Lare, Henry Hahn
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AssigneeArtech
InventorsRussell H. Rowe, Jr., Paul J. Lare, Henry Hahn
Estimating the term…
This biologically compatible surgical prosthetic implant has a multi-layer coating formed from metallic particles having sizes which increase in the direction from the metallic body of the implant toward the surface of the coating which is to interface with bone. The gradation is achieved by first depositing a layer of small particles, for example microspheres, of metallic coating material on the surface of the implant, then depositing progressively larger particles in subsequent layers. The particles may be deposited by any one of a number of well-known processes including but not limited to a flame-plasma process, in which several parameters are controlled as functions of the size of the particles. The resultant coating has minimum density and maximum porosity at its outer surface to encourage ingrowth of bone. The density of the coating is maximized at the interface between the coating and the body of the implant, thereby substantially matching the mechanical and thermal properties of the body of the implant and the coating and achieving optimum adherence of the coating to the body of the implant.
A posthetic implant comprising the combination of a metallic substrate and a coating on at least a portion thereof, in which such coating comprises first and second layers of metallic particles disposed with said first layer overlying and fused to said metallic substrate and said second layer overlying and fused to said first layer, wherein the sizes of said particles in said first layer are within the range (-100+400) mesh and wherein the sizes of said particles in said second layer are within the range (-60+150) mesh.
A prosthetic implant comprising the combination of a metallic substrate and a coating on at least a portion thereof, in which said coating comprises two layers of metallic particles disposed with the first such layer overlying and fused to the surface of said metallic substrate and forming the inner of said two layers, and with the second such layer overlying and fused to said first layer and being contiguous thereto and forming the outer of said two layers, the particles of said first layer having a first predetermined size within the range -100+400 mesh, the particles of said second layer having a second predetermined size within the range -60+150 mesh, and the mean value of said second predetermined size range being selected to be greater than the mean value of said first predetermined size range.
A method of coating a selected portion of the surface of a metallic prosthetic implant substrate comprising the successive steps of:
A prosthetic implant comprising the combination of a metallic substrate and a coating on at least a portion thereof, in which said coating comprises three layers of metallic particles disposed with the first such layer overlying and fused to the surface of said metallic substrate and forming the innermost of said three layers, the second such layer overlying and fused to said first layer and being contiguous thereto, and the third such layer overlying and fused to said second such layer and being contiguous thereto and forming the outermost of said three layers, in which the sizes of said particles of said first layer are within the range (-100+400) mesh, the sizes of said particles of said second layer are within the range(-60+150) mesh and the sizes of said particles of said third layer are within the range (-20+60) mesh.
Dependencies are inferred from the claim text.