# US 8,066,770 B2 · Sintered coatings for implantable prostheses

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 8,066,770 B2
- Document ID: US8066770B2
- Status: Granted
- Kind: B2
- Application number: 11/961,382
- Filed: 2007-12-20
- Published: 2008-12-04
- Granted: 2011-11-29
- Earliest claimed: 2007-05-31
- Assignees: DePuy Products, Inc.
- Inventors: Kori Rivard; Bernice Aboud
- Web page: https://patentgrep.com/patent/US8066770B2

## CPC

- A61F 2/30767: {Special external or bone-contacting surface, e.g. coating for improving bone ingrowth}
- A61L 27/306: {Other specific inorganic materials not covered by A61L27/303 - A61L27/32}
- A61L 27/56: Porous materials, {e.g. foams or sponges}
- B22F 7/004: {comprising at least one non-porous part}
- C23C 24/08: by application of heat or pressure and heat (C23C24/04 takes precedence)
- A61F 2/3094: {Designing or manufacturing processes}
- A61F 2/36: Femoral heads {; Femoral endoprostheses}
- A61F 2/3662: {Femoral shafts}
- A61F 2002/30011: {differing in porosity}
- A61F 2002/30929: {having at least two superposed coatings}
- A61F 2002/30968: {Sintering}
- A61F 2002/3631: {with an integral complete or partial peripheral collar or bearing shoulder at its base}
- A61F 2250/0023: differing in porosity
- A61F 2310/00017: Iron- or Fe-based alloys, e.g. stainless steel
- A61F 2310/00023: Titanium or titanium-based alloys, e.g. Ti-Ni alloys
- A61F 2310/00029: Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
- A61F 2310/00131: Tantalum or Ta-based alloys
- A61F 2310/00407: Coating made of titanium or of Ti-based alloys
- A61F 2310/00413: Coating made of cobalt or of Co-based alloys
- A61F 2310/00449: Coating made of chromium or Cr-based alloys
- A61F 2310/00497: Coating made of molybdenum or Mo-based alloys
- A61F 2310/00544: Coating made of tantalum or Ta-based alloys
- B22F 2998/00: Supplementary information concerning processes or compositions relating to powder metallurgy
- 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 (dental prosthetics A61C)
- 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 (preservation of bodies or disinfecting characterised by the agents employed A01N; preserving, e.g. sterilising, food or foodstuffs A23; preparations for medical, dental or toiletry purposes A61K)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- 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 (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)

## 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

### Claim 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.

### Claim 2 (depends on 1)

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

### Claim 3 (depends on 1)

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

### Claim 4 (depends on 1)

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

### Claim 5 (depends on 1)

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

### Claim 6 (depends on 1)

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

### Claim 7 (depends on 1)

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

### Claim 8 (depends on 1)

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

### Claim 9 (depends on 1)

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.

### Claim 10 (depends on 1)

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

### Claim 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.

### Claim 12 (depends on 11)

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.

### Claim 13 (depends on 11)

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.

### Claim 14 (depends on 11)

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

### Claim 15 (depends on 11)

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

### Claim 16 (depends on 11)

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

### Claim 17 (depends on 11)

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.

### Claim 18 (depends on 11)

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

### Claim 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.

### Claim 20 (depends on 19)

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.

### Claim 21 (depends on 19)

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.

### Claim 22 (depends on 19)

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

### Claim 23 (depends on 19)

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

### Claim 24 (depends on 19)

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

### Claim 25 (depends on 19)

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.

### Claim 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.

### Claim 27 (depends on 26)

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.

### Claim 28 (depends on 26)

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.