Method for producing open-porous bone implants made from fibers, with freely accessible guide structures made from fibers, which are formed from a biocompatible metal or metal alloy

Patent metadata

Field	Value
Publication number	US-2024191410-A1
Application number	US-202218553998-A
Country	US
Kind code	A1
Filing date	Mar 29, 2022
Priority date	Apr 6, 2021
Publication date	Jun 13, 2024
Grant date	—

Abstract

In the method for producing open-porous bone implants with freely accessible guide structures made from fibers, which are formed from a biocompatible metal or metal alloy, long fibers are superimposed in multiple layers, each in the form of a nonwoven, in which the fibers in each layer are arranged in a mutually preferred axial direction. Needling is carried out in at least one of the layers, by means of which individual fibers of the respective layer are aligned in an axial direction which differs by at least 60° from the preferred axial direction in which the other fibers of the layer are aligned. The superimposed layers are materially fitted to one another point by point via sinter bridges on fibers by sintering in a heating device.

First claim

1 .- 12 . (canceled)

13 . A method for producing open-porous bone implants, with freely accessible guide structures made from fibers, which are formed from a biocompatible metal or metal alloy, in which
long fibers are superimposed in multiple layers, each in the form of a nonwoven, in which the fibers in each layer are arranged in a mutually preferred axial direction, and needling is carried out in at least one of the layers, by means of which individual fibers of the respective layer are aligned in an axial direction which differs by at least 60° from the preferred axial direction in which the other fibers of the layer are aligned, and the superimposed layers are materially fitted to one another point by point via sinter bridges on fibers by sintering in a heating device.

14 . The method according to claim 13 , characterized in that layers, whose preferred axial direction, in which the respective fibers are aligned, differs from one another by at least 45°, are superimposed.

15 . The method according to claim 13 , characterized in that fibers of different layers, which are directly superimposed, are needled together.

16 . The method according to claim 13 , characterized in that layers with different densities and/or thickness in which the fibers are arranged and different porosities are superimposed prior to sintering.

17 . The method according to claim 13 , characterized in that, before and during sintering, the superimposed layers are subjected to compressive force by two opposite surfaces which are aligned perpendicular to the preferred axial directions in which the fibers of the layers are aligned.

18 . The method according to claim 13 , characterized in that a constant total thickness of the superimposed layers is maintained during sintering.

19 . The method according to claim 13 , characterized in that spacers are used to maintain the constant total thickness.

20 . The method according to claim 13 , characterized in that a semi-finished product is produced using the layers that are superimposed and sintered together, and at least one bone implant is separated from the respective semi-finished product using a separating process and brought into shape.

21 . The method according to claim 13 , characterized in that, prior to the separation, the interior of the semi-finished product is filled with an infiltrate, and the separation is carried out after the hardening of the infiltrate, and the infiltrate is removed again after the separation is carried out.

22 . The method according to claim 13 , characterized in that a non-crosslinking polymer, which is removed with a solvent, is used as the infiltrate.

23 . The method according to claim 21 , characterized in that a hard wax, which is thermally liquefied again and removed, is used as the infiltrate.

24 . The method according to claim 21 , characterized in that residual infiltrates are removed by thermal evacuation at a maximum temperature of 390° C. in an atmosphere containing air.

Assignees

• Rueger Matthias
• Fraunhofer Ges Forschung

Inventors

• Andersen Olaf
• Kostmann Cris
• Quadbeck Peter
• Fink Marcel
• Rüger Matthias

Classifications

• B32B2535/00

  Medical equipment, e.g. bandage, prostheses or catheter · CPC title

• B32B2305/20

  in the form of a non-woven mat · CPC title

• B32B2262/103

  Metal fibres · CPC title

• D04H1/74

  the fibres being orientated, e.g. in parallel {(anisotropic fleeces)} · CPC title

• D04H1/46

  by needling or like operations to cause entanglement of fibres (D04H1/45 takes precedence; needling machines D04H18/00) · CPC title