Dynamic porous coating for orthopedic implant

Patent metadata

Field	Value
Publication number	US-9750850-B2
Application number	US-201514879221-A
Country	US
Kind code	B2
Filing date	Oct 9, 2015
Priority date	Feb 9, 2012
Publication date	Sep 5, 2017
Grant date	Sep 5, 2017

Abstract

A dynamic porous coating for an orthopedic implant, wherein the dynamic porous coating is adapted to apply an expansive force against adjacent bone so as to fill gaps between the dynamic porous coating and adjacent bone and to create an interference fit between the orthopedic implant and the adjacent bone.

First claim

What is claimed is:

1. A method for providing therapy to a patient, the method comprising the steps of:
inserting an orthopedic implant into a bone cavity in a patient so that a dynamic porous coating applies an expansive force against an adjacent bone so as to fill gaps between the dynamic porous coating and the adjacent bone and to create an interference fit between the orthopedic implant and the adjacent bone, wherein the orthopedic implant comprises:
a substrate, the dynamic porous coating secured to the substrate, and a coating on the dynamic porous coating, wherein the dynamic porous coating comprises a plurality of layers, and the dynamic porous coating comprises a network of interconnecting pores.

2. The method according to claim 1 wherein the dynamic porous coating comprises a shape memory material or a superelastic alloy.

3. The method according to claim 2 wherein the shape memory material or the superelastic alloy is Nitinol.

4. The method according to claim 2 wherein the expansive force is created by superelasticity of the shape memory material.

5. The method according to claim 2 wherein the expansive force is created by a shape memory effect of the shape memory material.

6. The method according to claim 1 wherein the dynamic porous coating comprises a metal powder with a particle size between 10 μm and 200 μm.

7. The method according to claim 1 wherein the dynamic porous coating is formed of sintered layers of powder that create a three-dimensional porous coating.

8. The method according to claim 1 wherein the orthopedic implant includes a solid region for attachment to the substrate.

9. The method according to claim 1 wherein the dynamic porous coating has a major pore size between 500 μm and 600 μm and interconnecting pores between 150 μm and 300 μm.

10. The method according to claim 1 wherein the additively manufactured porous coating has a trabecular structure.

11. The method according to claim 1 wherein the dynamic porous coating has a dodecahedron structure.

12. The method according to claim 1 wherein the expansive force applied by the dynamic porous coating causes bone remodeling.

13. The method according to claim 1 wherein the orthopedic implant is inserted into the patient during revision surgery.

14. An orthopedic implant comprising:
a substrate, a dynamic porous coating secured to the substrate, and a coating on the dynamic porous coating,
wherein the dynamic porous coating comprises a plurality of layers,
wherein the dynamic porous coating comprises a network of interconnecting pores,
wherein the dynamic porous coating is adapted to apply an expansive force against adjacent bone, and
wherein the coating covers the dynamic porous coating.

15. The implant according to claim 14 wherein the dynamic porous coating comprises a shape memory material or a superelastic alloy.

16. The implant according to claim 15 wherein the shape memory material or the superelastic alloy is Nitinol.

17. The implant according to claim 15 wherein the expansive force is created by a superelasticity of the shape memory material.

18. The implant according to claim 15 wherein the expansive force is created by a shape memory effect of the shape memory material.

19. The implant according to claim 14 wherein the dynamic porous coating comprises a metal powder with a particle size between 10 μm and 200 μm.

20. The implant according to claim 14 wherein the dynamic porous coating is formed of sintered layers of powder that create a three-dimensional porous coating.

21. The implant according to claim 14 wherein the orthopedic implant includes a solid region for attachment to the substrate.

22. The implant according to claim 14 wherein the dynamic porous coating has a major pore size between 500 μm and 600 μm and interconnecting pores between 150 μm and 300 μm.

23. The implant according to claim 14 wherein the dynamic porous coating has a trabecular structure.

24. The implant according to claim 14 wherein the dynamic porous coating has a dodecahedron structure.

25. implant according to claim 14 wherein the expansive force applied by the dynamic porous coating causes bone remodeling.

26. The implant according to claim 14 wherein the orthopedic implant is inserted into the patient during revision surgery.

27. The method according to claim 1 wherein the coating is titanium or hydroxylapatite.

28. The method according to claim 1 wherein the coating is a tricalcium phosphate paste, the method including the steps of applying the tricalcium phosphate paste to the dynamic porous coating, compressing the dynamic porous coating with a compression force, drying the tricalcium phosphate paste to a tricalcium phosphate coating, and removing the compressive force.

29. The method according to claim 28 including the step of inserting the orthopedic implant in a medullary canal, dissolving the tricalcium phosphate coating in a solution, and allowing the dynamic porous coating to expand to fill gaps between the orthopedic implant and the adjacent bone.

30. The method according to claim 1 including the step of wrapping or sliding the dynamic porous coating over the substrate.

31. The method according to claim 1 including the step of modifying a surface of the dynamic porous coating to provide nano-texturing.

32. The implant according to claim 14 including the step of sintering a powder to a surface of the dynamic porous coating.

33. The implant according to claim 14 wherein the coating is titanium or hydroxylapatite.

34. The implant according to claim 14 wherein the coating is a tricalcium phosphate.

Assignees

• Mx Orthopedics Corp
• Arthrex Inc

Inventors

• Fonte Matthew
• Palmer Matthew

Classifications

• A61F2/34

  Acetabular cups · CPC title

• A61F2002/30092

  using shape memory or superelastic materials, e.g. nitinol · CPC title

• A61F2002/30915

  made of a stack of bonded perforated sheets, grids or wire meshes · CPC title

• A61F2/30907

  Nets or sleeves applied to surface of prostheses or in cement · CPC title

• A61F2/28

  Bones · CPC title