Pyrolytic carbon implants with porous fixation component and methods of making the same

Inventors: Brian H. Thomas (Auburndale, FL); Oludele O. Popoola (Granger, IN); Joseph R. Vargas (Garnerville, NY); Steven Seelman (Montclair, NJ); Jeffrey P. Anderson (Warsaw, IN)

Assignee: Zimmer, Inc.

A61F2/30767 A61F2/28 A61F2/30 A61F2/32 A61F2/34 A61F2/36 A61F2/3603 A61F2/38 A61F2/4003 A61F2/42 A61F2/44 A61F2002/3008 A61F2002/30011 A61F2002/3092 A61F2002/3098 A61F2002/30138 A61F2002/30143 A61F2002/30878 A61F2002/30981 A61F2310/00161 A61F2310/00395 A61F2310/00574 Y10T156/10

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Quick Facts

Patent No.: US 9,192,476
App. No.: 14/197,689
Granted: Nov 24, 2015
Kind: B2

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Abstract

An orthopedic implant including an articulation portion having a pyrolytic carbon bearing surface and a porous bone on- or in-growth structure, and methods of making the same.

Claims (33)

1. A method of forming an orthopedic implant, comprising:

providing or obtaining an implant core constructed as a single implant piece, said implant core including an articulation portion and a bone fixation portion, wherein only part of said bone fixation portion is porous for receiving to tissue ingrowth, said part including a porous region with a porosity of 55% to 90% which includes surface pores; and

applying a layer of pyrolytic carbon to an outer surface of the articulation portion.

2. The method of claim 1 , wherein said applying includes chemical vapor depositing the layer of pyrolytic carbon.

3. The method of claim 2 further comprising masking said bone fixation portion before applying the layer of pyrolytic carbon to the outer surface of the articulation portion.

4. The method of claim 1 further comprising applying a coating to said bone fixation portion, wherein said coating infiltrates pores in said bone fixation portion.

5. The method of claim 4 , wherein said coating is a metal coating.

6. The method of claim 5 , wherein said metal coating includes tantalum or a tantalum alloy.

7. The method of claim 1 , wherein the bone fixation portion includes a stem element.

8. The method of claim 7 , wherein the articulation portion forms an articulating head for use in a ball-and-socket joint.

9. The method of claim 1 , wherein the porous region extends no more than 2000 μm into the bone fixation portion from an outer surface of the bone fixation portion.

10. The method of claim 1 , wherein the implant core is constructed with carbon.

11. A method of forming an orthopedic implant, comprising:

providing or obtaining an implant core constructed as a single implant piece, said implant core including an articulation portion and a bone fixation portion, wherein only part of said bone fixation portion is porous for receiving tissue ingrowth, said part including surface pores; and

applying a layer of pyrolytic carbon to an exposed outer surface of the articulation portion while a mask is masking said bone fixation portion.

12. The method of claim 11 , wherein said part includes a porosity of 55% to 90%.

13. The method of claim 11 , wherein said applying includes chemical vapor depositing the layer of pyrolytic carbon.

14. The method of claim 11 further comprising applying a coating to said bone fixation portion while a second mask is masking said articulation portion, wherein said coating infiltrates pores in said bone fixation portion.

15. The method of claim 14 , wherein said coating is a metal coating.

16. The method of claim 11 , wherein the implant core is constructed with carbon.

17. The method of claim 11 , wherein the bone fixation portion includes a porous region that extends no more than 2000 μm into the bone fixation portion from an outer surface of the bone fixation portion.

18. A method of forming an orthopedic implant, comprising:

providing or obtaining an implant core constructed as a single implant piece, said implant core including an articulation portion and a bone fixation portion, wherein the entire bone fixation portion is porous with a porosity of 55% to 90%;

applying a layer of pyrolytic carbon to an exposed outer surface of the articulation portion while a mask is masking said bone fixation portion; and

applying a coating to said bone fixation portion while a second mask is masking said articulation portion, wherein said coating infiltrates pores in said bone fixation portion.

19. The method of claim 18 , wherein the implant core is constructed with carbon.

20. The method of claim 18 , wherein said coating is a metal coating.

21. A method of forming an orthopedic implant, comprising:

providing or obtaining an implant that includes an articulation portion and a bone fixation portion, wherein at least part of said bone fixation portion is porous for receiving tissue ingrowth;

applying a layer of pyrolytic carbon to an exposed outer surface of the articulation portion while a first mask is masking said bone fixation portion; and

applying a coating to said bone fixation portion while a second mask is masking said articulation portion, wherein said coating infiltrates pores in said bone fixation portion.

22. The method of claim 21 , wherein said coating is a metal coating applied by chemical vapor deposition.

23. The method of claim 21 , wherein the implant core is constructed with carbon.

Continuity (3)

Continuation 13246544 · Sep 27, 2011

Provisional Application 61387678 · Sep 29, 2010

Related Publication 20140188244A1 · Jul 3, 2014