Coatings for surgical instruments

Patent metadata

Field	Value
Publication number	US-2016186307-A1
Application number	US-201514983696-A
Country	US
Kind code	A1
Filing date	Dec 30, 2015
Priority date	Dec 30, 2014
Publication date	Jun 30, 2016
Grant date	—

Abstract

A coated medical instrument can include a first layer bonded to a metal substrate surface of a medical instrument, a second layer bonded to the first layer, and a third layer disposed on the second layer, The first layer comprises chromium (Cr), hafnium (Hf), titanium (Ti), and/or niobium (Nb). The second layer comprises a nitride, oxide, carbide, carbonitride, or boride of chromium (Cr), hafnium (Hf), niobium (Nb), tungsten (W), titanium (Ti), aluminum (Al), zirconium (Zr), and/or silicon (Si). The third layer comprises a nitride, oxide, carbide, boride, oxynitride, oxycarbide, or oxycarbonitride of chromium (Cr), hafnium (Hf), niobium (Nb), tungsten (W), titanium (Ti), aluminum (Al), zirconium (Zr), and/or silicon (Si). Methods for making coated medical instruments are also disclosed herein.

First claim

1 . A coated medical instrument comprising:
a first layer bonded to a metal substrate surface of a medical instrument, the first layer comprising chromium (Cr), hafnium (Hf), titanium (Ti), and/or niobium (Nb); a second layer bonded to the first layer, the second layer comprising a nitride, oxide, carbide, carbonitride, or boride of chromium (Cr), hafnium (Hf), niobium (Nb), tungsten (W), titanium (Ti), aluminum (Al), zirconium (Zr), and/or silicon (Si); and a third layer disposed on the second layer, the third layer comprising a nitride, oxide, carbide, boride, oxynitride, oxycarbide, or oxycarbonitride of chromium (Cr), hafnium (Hf), niobium (Nb), tungsten (W), titanium (Ti), aluminum (Al), zirconium (Zr), and/or silicon (Si).

2 . The coated medical instrument of claim 1 , wherein:
the first layer is 0.01 to 1.0 microns thick; the second layer is 1.0 to 5.0 microns thick; and/or the third layer is 0.01 to 5.0 microns thick.

3 . The coated medical instrument of claim 1 , wherein the first layer comprises metallic Cr, Hf, Ti, or Nb or a nitride or oxide of Cr, Hf, Ti, or Nb.

4 . The coated medical instrument of claim 1 , wherein the second layer comprises a nitride or oxide of Cr, Hf, Nb, W, Ti, Al, Zr, or Si.

5 . The coated medical instrument of claim 1 , wherein the third layer comprises Ti.

6 . The coated medical instrument of claim 1 , wherein the third layer is blue, grey, or black.

7 . The coated medical instrument of claim 1 , wherein the metal substrate surface is stainless steel.

8 . The coated medical instrument of claim 1 , wherein the second layer has a monoblock, multilayered, or gradient structure.

9 . The coated medical instrument of claim 1 , wherein:
the first layer comprises metallic Cr and the second layer comprises a nitride or oxide of Cr; the first layer comprises metallic Hf and the second layer comprises a nitride or oxide of Hf; or the first layer comprises metallic Nb and the second layer comprises nitride or oxide of Nb.

10 . The coated medical instrument of claim 9 , wherein the nitride or oxide of Cr, Hf, or Nb comprises a gradient.

11 . The coated medical instrument of claim 1 , wherein the coated medical instrument is corrosion resistant.

12 . A method for manufacturing a coated medical instrument comprising:
depositing a first layer on a metal substrate surface of a medical instrument by vapor deposition, the first layer comprising chromium (Cr), hafnium (Hf), titanium (Ti), and/or niobium (Nb); depositing a second layer on the first layer by vapor deposition, the second layer bonded to the first layer, and the second layer comprising a nitride, oxide, carbide, carbonitride, or boride of chromium (Cr), hafnium (Hf), niobium (Nb), tungsten (W), titanium (Ti), aluminum (Al), zirconium (Zr), and/or silicon (Si); and depositing a third layer on the second layer by vapor deposition, the third layer comprising a nitride, oxide, carbide, boride, oxynitride, oxycarbide, or oxycarbonitride of chromium (Cr), hafnium (Hf), niobium (Nb), tungsten (W), titanium (Ti), aluminum (Al), zirconium (Zr), and/or silicon (Si).

13 . The method of claim 12 , wherein at least one of the layers is deposited by an arc process or a combination of an arc and sputter processes.

14 . The method of claim 12 , wherein at least one of the layers is deposited at a temperature of 180 to 1,000° F.

15 . The method of claim 12 , further comprising a reactive plasma surface cleaning-conditioning process before depositing at least one of the first, second, and third layers.

16 . The method of claim 12 , further comprising external cleaning the metal substrate surface before depositing the first layer.

17 . The method of claim 12 , further depositing the second layer using an arc and sputter process, thereby depositing a gradient in the second layer.

18 . The method of claim 12 , further comprising depositing the first and second layers in a first vapor deposition chamber and depositing the third layer in a second vapor deposition chamber.

19 . The method of claim 12 , further comprising cleaning and conditioning a surface of the second layer using a plasma cleaning technique before depositing the third layer.

20 . The method of claim 12 , wherein the coated medical instrument is corrosion resistant.

Assignees

• Depuy Synthes Products Inc

Inventors

• Sukadhare Dayananda
• Selover Sean

Classifications

• C23C14/0068

  characterised by means for confinement of gases or sputtered material, e.g. screens, baffles · CPC title

• C23C14/0089

  in metallic mode · CPC title

• A61L2430/38

  for reconstruction of the spine, vertebrae or intervertebral discs · CPC title

• A61L31/082

  Inorganic materials · CPC title

• A61L27/306

  Other specific inorganic materials not covered by A61L27/303 - A61L27/32 · CPC title