Bioimplant with antibacterial coating and method of making same

Patent metadata

Field	Value
Publication number	US-10814039-B2
Application number	US-201715405156-A
Country	US
Kind code	B2
Filing date	Jan 12, 2017
Priority date	Feb 3, 2012
Publication date	Oct 27, 2020
Grant date	Oct 27, 2020

Abstract

Provided is a bioimplant which is capable to inhibit the biofilm formation over a long period of time after an operation. The bioimplant of the present invention comprises a base material of metal, ceramic, or plastic and a thermal spraying film of a calcium phosphate-based material formed at least partially thereon and the silver concentration in the thermal-spray film is 0.05 wt % to 3.00 wt %.

First claim

What is claimed is:

1. A method of manufacturing a bioimplant, comprising:
providing a base material of the bioimplant;
applying a thermal sprayed film comprising a calcium phosphate-based material and a silver material to form a coating on at least a part of a surface of the base material;
after applying the thermal sprayed film, heating the coating at a temperature range of 400 to 1000 degrees Celsius under a reduced pressure of less than 10 −2 Pa to form oxyapatite in the coating; and
immersing the coating in purified water to convert oxyapatite present in the coating to hydroxyapatite, wherein a temperature of the purified water is in a range of 60 to 100 degrees Celsius, and wherein the resulting coating comprises a silver concentration in the range of 0.05 wt % to 3.00 wt %.

2. The method according to claim 1 , wherein said calcium phosphate-based material is a compound or a mixture of two or more compounds selected from the group consisting of hydroxyapatite, .alpha.-tricalcium phosphate, .beta.-tricalcium phosphate, and tetracalcium phosphate.

3. The method according to claim 1 , wherein the base material comprises a metal.

4. The method according to claim 1 , wherein the base material comprises ceramic.

5. The method according to claim 1 , wherein the base material comprises a plastic.

6. The method according to claim 1 , wherein crystals of calcium phosphate are formed on a surface of the coating as a result of the immersing, thereby reducing a rate of elution of silver ions from the coating.

7. The method according to claim 6 , wherein a size of the crystals of calcium phosphate is in a range of 0.01 μm to 2.00 μm in length, thickness or width.

8. The method according to claim 1 wherein the heating is performed for a period in the range of 0.5 to 7 hours.

9. The method according to claim 8 wherein the heating is performed at a temperature range of 550 to 850 degrees Celsius for a period in the range of 1 to 5 hours.

10. The method according to claim 1 wherein the immersing is performed for a period of time in the range of 10 to 60 minutes.

11. A method of manufacturing a bioimplant, comprising:
providing a base material of the bioimplant;
applying a coating on at least a part of a surface of the base material, wherein the coating comprises a silver concentration in the range of 0.05 wt % to 3.00 wt %;
after applying the coating, heating the coating to form oxyapatite in the coating, wherein the heating is performed at a temperature range of 400 to 1000 degrees Celsius under a reduced pressure of less than 10 −2 Pa; and
immersing the coating in purified water to convert the oxyapatite to hydroxyapatite, wherein a temperature of the purified water is in a range of 60 to 100 degrees Celsius, and wherein crystals of calcium phosphate are formed on a surface of the coating as a result of the immersing, thereby reducing a rate of elution of silver ions from the coating.

12. The method according to claim 11 wherein:
the heating is performed at a temperature range of 550 to 850 degrees Celsius for a period of time in the range of 1 to 5 hours;
and
the immersing is performed for a period of time in the range of 10 to 60 minutes.

Assignees

• Univ Saga
• Kyocera Medical Corp
• Kyocera Corp

Inventors

• Mawatari Masaaki
• Tsukamoto Masatsugu
• Noda Iwao

Classifications

• A61L2300/104

  Silver, e.g. silver sulfadiazine · CPC title

• A61L27/32

  Phosphorus-containing materials, e.g. apatite · CPC title

• A61L27/54 Primary

  Biologically active materials, e.g. therapeutic substances {(A61L27/227 takes precedence)} · CPC title

• A61L2300/404

  Biocides, antimicrobial agents, antiseptic agents · CPC title

• A61L2420/02

  Methods for coating medical devices · CPC title