POROUS FLEXIBLE METAL FIBER MATERIAL FOR SURGICAL IMPLANTATION

Abstract: Titanium or other biocompatible metal fibers having a diameter of from about 20 to about 200 µm, a length of from about 2 to 50 mm and a length-to-diameter ratio of at least about 100 are formed into a flexible and deformable mass, for example, a sheet, of interlocked fibers, which may be sintered for additional coherence, to a thickness of from about 0.5 to 30 mm. The amount of fibers is such that the sheet has a voids volume of at least 65% preferably about 90%. The diameter of the pores of the porous sheet are at least about 150 µm such that bony tissue can grow in the pores. These porous sheets are highly malleable without loss of structural integrity or pore size distribution. Accordingly, the porous metal fiber mesh sheets are useful for stabilizing prosthetic devices or for general repair of defective bone structures.

Description: This invention relates to a new biocompatible porous metal fiber mesh material which is useful in reconstructive bone surgery, that is implantation surgery for repairing or replacing a defective bone, and which has the function of allowing bone tissue ingrowth into the mesh material for the purpose of stabilizing the reconstructed bone. It is known to provide various forms of prosthetic devices such as hip prostheses with porous surfaces including sintered metal fibers to provide a bone ingrowth surface by which the surrounding natural bone tissue can grow into the porous material to stabilize the implanted device. For example, US-A-3,992,725 discloses a fiber material having a preferred composition of carbon and graphite fibers, and optionally metallic and ceramic fibers, bonded together by sintered polytetrafluoroethylene (PTFE). This material is bonded to the surface of an implant to stabilize the implant by fostering ingrowth of bone tissue. Document US-A-4,064,567 discloses a mesh sheath woven of metal wire such as titanium, stainless steel and chrome cobalt. The sheath is used as a reinforcing element with bone cement to arrest crack formation and maintain the shape and integrity of the cement when that cement is used for bonding an implanted device. US-A-3,906,550 discloses a prosthetic device comprising a fiber metal structure of sufficient section to support loads adequately or else a solid load-carrying member having a porous fiber metal structure secured to the surface thereof. The porous fiber metal structure is produced by molding and sintering short metal fibers which are preferably kinked prior to being cut into short fibers. In practice, the short metal fibers are mechanically molded into the desired precise shapes using constraining dies and moving punches to produce a three-dimensionally mechanically interlocked network of fibers which is then sintered. The sintered fiber metal aggregates have a porosity ranging from 10 to 70% and preferably from 40 to 50% per unit area. The starting metal wires can have a length ranging from 1.3 to 3.8 cm (from 13 to 38 mm) and a diameter ranging from 0.013 to 0.030 cm (from 130 to 300 µm). US-A-3,605,123 discloses a prosthetic device having a porous metal surface layer on a dense base of the same metal. The porous surface layer has been formed by means of a plasma spraying process in such a way that the density of that surface layer is greatest (substantially pore-free) at the interface with the base and becomes progressively larger towards the exterior surface. A different approach is used in US-A-3,048,703, where a region of controlled porosity is provided on the exterior surface of a prosthetic device by securing a metal coil spring to the exterior surface. A structure having varying degrees of porosity, ranging from highly dense at its interior surface to highly porous at its exterior surface, is disclosed in EP-A-0016480. According to this document, a fluid-tight stocking-like liner or inner bag has a textured surface layer obtained by winding filaments of the same material as the liner around that liner while the latter is still on the core on which it is formed. The stocking-like inner bag with textured (porous) surface can be used for anchoring the shaft of an endoprosthesis by means of bone cement placed inside the bag while the surface structure promotes tissue ingrowth. A stocking-like prosthetic device is also disclosed in DE-A-2,842,847. According to this document, a funnelshaped mesh prosthesis can be formed from intersecting and interconnecting steel wires or filaments which permit some deformation in a direction perpendicular to the surface of the mesh and to a lesser degree in the plane of the mesh. The present inventor has previously provided a porous compound material for prosthetic devices in GB-A-2,059,267. The porous compound material includes at least one layer of metal wire mesh joined to a metal substrate by means of a metallurgical bonds at the points of contact. While several of these and other porous materials have been used with varying degrees of success as or in conjuction with prosthetic devices for surgical implantation, there remains a need for porous biocompatible materials which do not require preforming into a specific shape or configuration or bonding to a base metal and which are highly flexible and deformable so as to permit use in a broader variety of applications than previously possible. It would also be desirable to provide a porous bone tissue ingrowth material which can be configured to more closely conform to the bone surface that the material bears against while, at the same time, not being restricted to specific types of surgical procedures such as would be the case for the stocking-like prosthetic devices of DE-A-2,842,847 and EP-A-0,016,480 which are effectively limited to hip-joint endoprostheses. One such attempt to provide a flexible porous fiber material suitable for implantation and for bone ingrowth is described in the above mentioned document US-A-3,992,725. This patent discloses a porous carbon fiber-polytetrafluoroethylene composite which is sold commercially under the trademark "Proplast". According to the literature accompanying this product, the flexible non-metallic fiber composite has an inter-connecting pore size greater than 200 µm which is a generally acceptable value for bone tissue ingrowth. However, as reported by Spector et al in Journal of Biomedical Materials Research, Vol. 13, 677-682 (1979), and references cited therein, only fibrous tissue, not bone, will form in the internal pores of Proplast. The analysis by Spector et al showed that Proplast has an average pore size of only 75 µm and interconnecting pores of less than 50 µm in diameter. It was concluded that the pore size configuration was an inherent result of the fabrication process in which pores are produced by dissolving salt crystals, which are introduced into the mix of carbon fibers and PTFE, prior to compression, rolling and sintering. A major problem in total hip prosthesis is the tendency for one or both of the components (femoral component and acetabular component) to loosen during use. This loosening can result, for example, from bone resorption or degradation of the bone cement. Whatever the cause, when such loosening occurs, a marked bone erosion can result and it becomes necessary for the patient to undergo revision surgery. However, revision of a loosened implant is a difficult procedure and present techniques are not entirely satisfactory. For instance, revision of the femoral component is generally accomplished by one of the following procedures. A femoral prosthesis similar to the original is reinserted and the cavity is filled up with a thicker cement layer. The problem with this procedure is that it is generally accepted that the cement thickness may not exceed 5 millimeters at most. With more cement, the maximum temperature during polymerization is conducive to heat necrosis of surrounding bone tissue. Also, a thicker cement layer is generally considered to be more susceptible to stress cracking failures and to have inferior mechanical properties in general. As an alternative, a thicker prosthesis has been used with more normal cement thicknesses, e.g. 3 millimeters. However, by using a thicker metallic stem an unacceptably large proportion of the joint load is carried by the implant rather than by the bone. This is due, in part, to the much higher modulus of elasticity of the metal relative to the bone. A lack of stress in the bone can lead to disuse atrophy. Thus, there will be a high tendency for the newly implanted prosthesis to loosen again due to endosteal resorption. It has also been proposed to use a wire mesh to reinforce the thicker cement layers to improve their limited strength, but in that case, there are still the problems of high polymerization temperatures and various cytotoxic reactions to the cement. The funnel-shaped mesh of DE-A-2,842,847 is filled with bone cement during use, and with the prosthetic shaft inserted therein, the assembly is inserted in the receiving bone cavity. Although the filamentary form of the mesh permits some deformation, there is still no attempt to have the mesh conform closely to the bone cavity nor is bone ingrowth into the mesh contemplated. Rather, the mesh is principally designed to reinforce the cement. The stocking-like liner of EP-A-0,016,480 would appear to offer some improvement in this regard since the liner is sufficiently thin and flexible to permit deformations to conform to the bone cavity when the bag is expanded upon insertion of cement and the prosthetic shaft in the impervious inner bag while the outer textured porous surface permits bone tissue ingrowth. However, while the impervious liner avoids some of the problems caused by the heat of polymerization and the cytotoxicity, there still remains the problem of load distribution between bone, cement and metal prosthesis. In addition, as previously mentioned, these liners are of only limited utility in endoprosthesis. For the acetabular component, the present procedure is simply to fill up the available spaces by cement. Apart from the previously noted disadvantage of too thick a cement layer, there also is the problem of insufficient bone stock to retain the cemented acetabular cup. The porous metal fiber structure of US-A-3,906,550 can be used to fill the acetabular cavity and be fixed thereto by bone tissue ingrowth. While achieving substantial success, there still is the problem that the material is substantially rigid and not deformable and must be molded precisely to the configuration of the particular cavity and, if necessary, subjected to repressing procedures to achieve a zero clearance fit. Accordingly, it is an object of this invention to provide a porous deformable and flexible biocompatible material having broad application to reconstructive surgery including repair and/or replacement of defective or damaged bone structure. It is another object of this invention to improve the methods of reconstructive bone surgery by providing a flexible bone tissue ingrowth material which can be closely conformed to the surface(s) of the healthy bone being reconstructed, as well as to the geometry of the artificial prosthetic device, in the case of bone replacement surgery, by pressing the flexible material against the surface(s) of the healthy bone being reconstructed. In order to accomplish these objects, the present invention provides a biocompatible porous metal fiber mesh material which is useful in reconstructive bone surgery, said material consisting essentially of a multiplicity of biologically inert metal fibers which are interengaged and intertwined with each other to form a porous mesh, and the mesh having a porosity such that bone tissue can penetrate into the pores of the mesh when such mesh is pressed against the surface of the skeletal structure of a living human or animal, characterized by the fact: that said mesh material is in the form of a sheet having a thickness in the range of from 1 to 15 millimeters and a porosity in the range of from 80% to 92%, each of the metal fibers in said sheet having a length in the range of from 2 to 50 millimeters, a diameter in the range of from 40 to 100 µm, and a length-to-diameter ratio of at least 125, said porous sheet being flexible and deformable by simple hand manipulation without losing its structural integrity. The porous fiber mesh material of the invention has pore sizes such that bone tissue can penetrate into the pores thereof when the porous mesh is pressed against living bone. Yet, it is capable of undergoing substantial bending and shaping without losing its structural integrity, including pore size distribution and volume density. In a preferred embodiment, the metal fibers in the porous fiber mesh material have been sintered at their points of contact. With the aid of this invented porous metal fiber mesh material, the conventional method of replacing a defective portion of a human or animal skeleton with an artificial prosthetic device, such as an artificial hip joint, can be improved. Supposing that the defective portion has been surgically removed to form a receiving surface in the remaining portion of the skeleton for mating with the prosthetic device, the improved method is accomplished by pressing the inverted sheet of porous fiber mesh material onto the receiving surface in order to have it conform to the shape of that surface, forming a layer of bone cement on the exposed surface of the mesh material and placing the prosthetic device against the layer of bone cement to thereby force the cement into the pores of the fiber mesh. The bone cement will penetrate only through a portion of the total thickness of the fiber mesh material, and an immediate stabilization of the prosthetic device is accomplished by setting of the bone cement. Longterm stabilization is provided then by ingrowth of bone tissue into the pores of the mesh material which are in contact with the receiving surface of the healthy bone. In repairing or reconstructing a defective bone structure including one or more cracks or voids or other openings or spaces, the cracks or voids are simply filled with the above described porous metal fiber mesh material with or without addition of bone cement such that the porous fiber mesh closely conforms to the surfaces of the healthy bone in the vicinity of the cracks or voids whereby bone tissue can grow into the pores of the porous mesh. The invention will now be described in greater detail with reference to specific embodiments thereof and with the aid of the accompanying drawings in which: fig. 1 is a scanning electron microscopic image (magnification 50 x) of a porous fiber mesh material according to the invention; fig. 2 is a cross-sectional micrograph of the porous fiber mesh material shown in fig. 1; fig. 3 shows a typical load displacement curve for a porous fiber mesh material according to the invention; fig. 4 is a perspective view of a typical specimen of the invented fiber mesh material; fig. 5 is a schematic cross-sectional view of the fiber mesh material implanted in the femoral canal with cement; fig. 6 is a schematic cross-sectional view of the invented fiber mesh material used with a hip prosthesis; and fig. 7 is a schematic cross-sectional view of the invented fiber mesh material used with an acetabular prosthesis. Any material for surgical implantation must necessarily meet certain criteria. Several of the criteria are mentioned in US-A-3,992,725 and include biocompatibility, resistance to chemical migration when implanted, stability for autoclaving, porosity for bone tissue ingrowth and resiliency. In addition thereto, a satisfactory porous material for implantation should naturally have sufficient strength characteristics to withstand and accomodate a wide range of stresses. In particular, the strength of the porous material, as well as the bonding between the porous material and the bulk implant, must exceed the stress levels that are expected to be encountered in vivo . It is also preferred that the implanted porous material should possess elastic properties approaching those of the surrounding tissues in order to minimize the stress peaks at the interface between the porous material and the insert. The porous metallic fiber mesh material according to the invention satisfies all of the foregoing requirements. Biocompatibility and resistance to chemical migration and stability for autoclaving are all provided by selection of appropriate metals for the metallic fibers. Many of such metals have been known for use in surgical devices, such as for example cobalt-chromium alloys, titanium, tantalum, niobium, alloys of these metals, and the like. Titanium is the preferred metal since its biocompatibility is well documented and in addition its low modulus of elasticity increases the overall flexibility of the porous sheets produced from the titanium fibers. Other metal fibers, such as stainless steel fibers may also be used for certain applications but because of the possibility of crevice corrosion inside the interstices of the porous material, the use of stainless steel fibers is not generally recommended. Since the porous metal fiber mesh material is produced without addition of chemical binders or other fibers and since these biocompatible materials are highly inert to body fluids, there is substantially no likelihood of chemical migration of the implanted porous material. In addition to possessing the foregoing properties, the porous metal fiber mesh material has the properties of being flexible and being highly deformable by simple hand manipulation. That is, the porous mesh material of the invention is capable of being deformed without loss of structural integrity and without diminution of pore volume or pore size. It can be easily deformed to the desired configuration at the time of surgery using available instruments and acceptable operating room procedures. Therefore, unlike prior porous insert materials, it is not necessary to preform the porous mesh by complicated molding or other shaping procedures and it is also not necessary to bond the shaped porous mesh to the orthopedic or prosthetic appliance or wear surface. According to this invention, the critically important characteristics of pore size and deformability are achieved by careful control and selection of the following three parameters of the porous metal fiber mesh material: 1. fiber diameter and fiber length; 2. thickness of the porous mesh sheet; and 3. porosity or volumetric density of the porous mesh sheet. In general, the deformability, or malleability, of the porous mesh sheet can be improved by decreasing the volumetric density (i.e. increasing porosity) and by decreasing the thickness of the porous mesh sheet. However, the volumetric density and thickness parameters cannot be decreased in an unlimited way since other characteristics of the porous mesh are also affected by these parameters. Therefore, it is necessary to limit the above parameters to within well defined and critical limits. 1. Fiber diameter and length: as the fiber diameter is decreased, the mesh sheet becomes flexible and deformable but the pore size also becomes smaller. The fiber length must be controlled to provide a balance between coherence and flexibility. The fiber length should be within the range of from 2 millimeters to 50 millimeters, preferably from 2.5 millimeters to 30 millimeters and more preferably from 8 millimeters to 25 millimeters. The fiber diameter should be within the range of from 40 µm to 100 µm. If the fiber length is less than 2 millimeters, it is difficult to produce a coherent mass of fibers. If the fiber length is more than 50 millimeters, the manufacturing process becomes difficult. In particular, for fiber lengths in excess of 50 millimeters, sieving the fibers becomes impractical if not impossible. If the diameter of the fibers is less than 40 µm, it becomes difficult to maintain the average pore size of at least 150 µm needed to assure ingrowth of bone tissue. If the fiber diameter is greater than 100 µm, the flexibility and deformability become insufficient. Within these ranges of fiber length and diameter, it is preferred that the fiber length-to-diameter ratio be at least 125 and preferably at least 200. Thus, for a given diameter fiber, the fiber length should be selected to give an L/D ratio which will ensure a coherent mass of fibers. 2. Thickness: as the thickness of the porous fiber mesh sheet decreases, the fiber mesh material becomes more flexible, but below 1 mm, the coherence of the fiber mesh becomes unsatisfactory with thick fibers. At a thickness above 15 mm, the porous mesh can not readily be deformed. Accordingly, the thickness of the porous mesh should be within the range of from 1 mm to 15 mm. 3. Porosity: as the porosity increases (volumetric density decreases), both flexibility/deformability and pore size increase, but the coherence of the fiber mesh decreases. The porous fiber mesh material according to the invention has an unusually high porosity in the range of from 80% to 92%. As used herein, and in the appended claims, "porosity" refers to the voids or pore volume of the porous fiber mesh and is the converse of the "volumetric density" which is the amount, by volume, of fibers per unit volume of the porous fiber mesh sheet. Thus "porosity" (%) = 100% - "volumetric density" (%). Furthermore, the porosity or volumetric density may vary slightly from region to region of the porous metal fiber mesh and it is sufficient if the average value of porosity or volumetric density over the entire cross-section of the porous fiber mesh falls within the foregoing values. Similarly, it is possible for a small amount, for example, less than 20% by weight, preferably less than 10% by weight, especially preferably less than 5% by weight, of the total fibers to have diameters and/or lengths and/or length-to-diameter ratios outside of the values specified above, so long as the average values fall within the prescribed limits. In order to improve the coherence of the porous metal fiber mesh and to prevent or at least minimize the displacement of individual fibers within the mesh, or even the complete removal of individual fibers from the mesh, it is preferred to subject the porous mesh to a heat treatment sufficient to sinter the individual metal fibers to each other. The sintering operation is a solid state diffusion process by which metal to metal bonds are formed between individual fibers. While the sintering operation results in some reduction in flexibility and deformability by virtue of the metal to metal bonds which restrains the relative displacement of the fibers, this reduction is offset by the reduction in loss of fibers during handling and implantation. The porous metal fiber mesh material can be fabricated by usual techniques including sieving the fibers to the appropriate size range, compacting the fibers into a sheet-like structure and preferably sintering. In the compacting step, the amount of fibers needed is calculated based on the average fiber size and the desired thickness and porosity (or volumetric density) of the resulting sheet. The amount of fibers needed to fill the available space can be readily calculated or determined by routine experimentation. After the metal fibers are sieved, they can be directly laid down on a suitable surface, e.g. a mold to form a loosely packaged mass of interlocked metal fibers, or they may be mixed with a suitable liquid to form a slurry of the fibers. In the latter case, the slurry is then filtered through appropriately sized filter paper to form a loosely packed sheet of interlocked metal fibers. The loosely packed sheet, after removal of the remaining liquid, if present, is compressed between flat surfaces, one or both of which may be heated to remove any residual liquid until the predetermined thickness is reached. The amount of pressure to be applied will depend on various factors such as the type of fiber, thickness and porosity, but generally pressures in the range of from 4 to 200 MPa are satisfactory. Alternatively, the sieved fibers may be picked up and laid down from an air slurry according to known techniques. In forming the fiber slurry, filtering the slurry, compacting, sintering and any other steps in handling or treating the metallic fibers, some degree of care should be taken to avoid substantial bending or twisting of the fibers out of their informal linear configuration since the flexibility and deformability of the resulting product will decrease as the fibers become more nonlinear, presumably as a result of the greater number of contact points between fibers per unit area. For example, a sheet of the porous metal fiber mesh having a thickness of 3 mm and an average density of 10 to 15% can be prepared from commercial purity titanium fibers having an average diameter of 50 µm and an average length of 20 mm by first sieving the fibers to deglomerate any clumps or masses. The sieved fibers are directly fed into an appropriately sized vessel, for example, measuring 15 cm x 15 cm, while exercising care to obtain a uniform distribution of the fibers and avoid reagglomeration. A sufficient amount of fibers is deposited to obtain a thickness of from 4 to 5 cm. This loose mass of fibers is transferred to a hydraulic press having two platens, each measuring 12 x 6 cm, and the mass is subjected to a pressure of about 6 to 10 MPa, preferably about 8 MPa, for 1 to 10 seconds, preferably 2 to 4 seconds. The edges of the resulting sheet are cut off by the press to obtain 2 sheets, each measuring 120 x 60 x 3 mm. Preferably, the porous metal fiber sheets are then sintered to improve the cohesion by forming metal to metal bonds at the fiber cross-over points. Sintering can be carried out, for example, by placing the fiber sheets, laid between Al₂O₃ plates of about 300 g each, in a vacuum furnace (e.g. at 10⁻⁴ torr or lower), which is heated to about 900°C for about 30 minutes. By using metal fibers within the size limitations described above and controlling the amount of fibers in the porous mesh to provide the thickness and porosities described above, the porous mesh will have a pore size distribution such that at least 50 percent, preferably at least 80 percent, especially preferably about 100% of the pores will have a pore size of at least 150 µm, preferably from 150 µm to 600 µm. As used herein "pore size distribution" refers both to the pores at the surface of the fiber sheet and throughout the thickness of the fiber sheet. For a porous fiber material with an average porosity of as high as 80 to 90% it is difficult to exactly define what the pore size is. To appreciate the difficulty, it may be helpful to consider both a scanning electron microscopic image (fig. 1) and a cross-sectional micrograph of a typical porous material with a 90% porosity (fig. 2). The cross-sectional micrograph shows the abundance of porosity. It would be logical to determine a pore dimension parallel with the surface of the sheet since the efficacy of either bone cement intrusion or bone ingrowth would primarily depend upon the pore dimension perpendicular to the intrusion or ingrowth direction. A widely used method to measure such dimensions is a stereometrical method: the line intercepts of pores are measured on micrographs on a set of lines that are projected on the micrograph, independently from the analyst. However, with the present porous material this is bound to yield data without physical meaning; for example, in fig. 2 various possible intercepts without meaning are indicated by an "X". That is, these pores are not accessible over their entire length, i.e. are blocked by other fibers, for bone ingrowth or cement intrusion. From these considerations, it appears appropriate to indicate an estimate for the range of available pore sizes. This can be obtained from the scanning micrograph: the fibers in fig. 1 have a diameter of 50 µm. Interstices range from 100 to 600 µm and predominantly from 150 to 600 µm. In addition to the pore size distribution being sufficient to permit ingrowth of bone tissue, the fiber mesh implant material has a porosity and pore size distribution which permits bone cement to pentrate through the interstices of the mesh using slight thumb pressure. For example, the bone cements contemplated include substantially all types of bone cements now used in surgical procedures. The most common of these are bone cements based on polymethyl methacrylate, generally a combination of polymer powder and liquid monomer which polymerizes in situ . Bone cements may be of the high viscosity type, i.e. having viscosities ranging from 1000 to 4000 cps, or of the low viscosity type, having viscosities ranging from 10 to 1000 cps. The bone cements preferably have a viscosity such that during surgery the cement will penetrate through only a portion of the thickness of a porous metal fiber mesh sheet, generally from 1/10 to 1/2, preferably from 1/4 to 1/2 of the thickness of a fiber sheet so that sufficient volume remains in the bone facing side of the sheet to permit bone tissue ingrowth. Polymethylmethacrylate bone cements having viscosities (before setting) in the range of from 1000 to 4000 cps are preferred, such as, for example Zimmer® Bone Cement, Catalogue No. 1102-02, (40 grams polymer powder and 20 grams monomer liquid). The porous metal fiber mesh material 1 is provided in sheet form, such as shown in figure 4. A typical large sheet may, for example, have dimensions of 60 x 120 x 3 mm, and can be cut into smaller sizes, or folded upon itself into two or more layers, as necessary. It is also possible, due to the flexibility of the porous fiber mesh material, to form continuous length sheets which can be stored in rolled up form and dispensed in suitable lengths, as needed. The flexible porous metal fiber mesh of the invention has a broad range of applications in bone surgery such as for example: mandibular reconstruction including fixation of artificial teeth, revision surgery of the hip joint and other joint prostheses and implant procedures, and, in general, any procedure where a normal regrowth of bone tissue cannot be expected. In the case of mandibular reconstruction, a cavity is prepared in the jawbone and the cavity is manually filled with the porous metal fiber mesh in an amount sufficient to augment or reconstruct the mandibular. Where there is insufficient bone to form a cavity it may be necessary to provide means for initial stability. The stabilization means can take the form of suture wires or bone cement, for example. The flexibility and deformability of the porous material permits the metal fiber mesh to be closely conformed or adapted to the existing bone surfaces, as well as to the desired final configuration for reconstruction. It is a distinct advantage of the porous material of this invention that the precise shaping can be easily accomplished during the surgical procedure without destruction of the pore size distribution required for bone tissue ingrowth. For revision surgery of the femoral component, a hip prosthesis with a normal stem thickness can be used by pressing one or more layers of porous fiber mesh material in the previously prepared femoral canal against the bone while leaving a central opening to receive the hip stem with sufficient room to surround the stem with a thickness of bone cement of from about 1 mm to about 4 mm. As seen in figure 5, two layers 10 and 11 of the porous fiber mesh sheets, each having a thickness of 4 mm, are pressed against and conformed to the cortical bone 19. The resulting cavity is filled with bone cement 16 and the hip stem 18 (figure 6) is then fitted centrally within the cavity thereby causing a portion of the cement to penetrate into the inner layer 11 of the porous sheet material as shown at 14. The thickness of the bone cement between the inner layer 11 and the surface of the stem 18 ranges from 1 to 4 mm depending on the diameter of the femoral canal. If necessary, to accommodate the tapering diameter of the femoral canal, it may be sufficient to use fewer layers of the porous material at the bottom end of the femoral canal than at the higher and wider end of the femoral canal. Accordingly, it is possible to use both a normal thickness of bone cement and a normal thickness of the metal hip stem. In view of the ability to shape the porous mesh material, it can be closely contacted with the bone without closing the pores of the mesh material. Thus, long term stabilization of the hip prosthesis is accomplished as the cortical bone grows into the pores of layer 10 as shown at 15 while immediate stabilization between the stem and mesh material is provided upon setting of the bone cement against the stem and in the pores of layer 11. A still further advantage of the mesh material of this invention is that its modulus of elasticity closely approximates that of the bone. This substantially eliminates the risk of having greatly alterned stress levels in the cortex. The mechanical and elastic properties of a typical porous mesh material of the invention made from titanium fibers of 50 µm diameter and 20 mm length at a density of about 10% (90% pore volume) and a sheet thickness of 3.5 mm, sintered at 900°C for 30 minutes, is determined as follows: A specimen measuring 14 mm x 120 mm is supported from below at two points 90 mm apart, 15 mm inwards from each end. Two load points are spaced 50 mm apart, 35 mm inwards from each end. Measurements of load displacement are made with an Instron TT-DM-L testing machine at a cross head speed of 5 mm/min. A typical load displacement curve is shown in figure 3. It shows two loading-unloading cycles; the first one is shown in full line, the second one is shown as a dotted line. After unloading, there is a permanent deformation as shown in fig. 3. This permanent or residual deformation (δ r ) is at most only half of the maximum or total deformation (δ t ). This clearly shows the excellent deformability of the material. The second loading cycle of fig. 3 is characterized by a maximum force F of 3.65 N. The maximum stress in the porous sheet at that moment is 2.8 MPa and the total deformation δ t = 13.8 mm. Upon unloading, the residual deformation is δ r = 6.3 mm. The apparent modulus of elasticity can be defined from the plot as the slope of the loading portion of the graph. The modulus thus defined represents the apparent elasticity of the porous sheet in the plane of the sheet. Values between 80 and 100 MPa were measured; the variation may be accounted for by slight variations in density. These data substantiate the fact that the elasticity of the porous fiber mesh is close to the elastic properties of trabecular bone into which it is implanted. For an acetabular prosthesis, as shown in figure 7, the acetabular floor 20 is covered with at least one layer 22 of the porous mesh material. A layer of polymer methacrylate bone cement 24 is provided on the porous mesh layer and the acetabular prosthesis, for example, a high density polyethylene cup prosthesis 26, is placed on the cement with sufficient pressure to force the viscous bone cement into at least the pores on the surface of the porous fiber mesh material, as shown at 27, to provide initial stabilization. Long term stabilization is provided as bone tissue grows into the pores of the mesh, for example, to a depth shown by dotted line 28, which has been placed in close contact and conformity with the bone stock of the acetabular floor. For general bone repair the porous material can be used as a bone filling material by packing it into a defect or void in the bone. If desired, after positioning of the porous mesh material, a bone cement can be injected to penetrate throughout the interstices of the porous mesh. The volume of cement can be determined to fill up all or only a portion of the available volume. This can result in a composite reinforced cement of improved toughness and strength while still allowing bone tissue ingrowth.

Claims: A biocompatible porous metal fiber mesh material which is useful in reconstructive bone surgery, said material consisting essentially of a multiplicity of biologically inert metal fibers which are interengaged and intertwined with each other to form a porous mesh, and the mesh having a porosity such that bone tissue can penetrate into the pores of the mesh when such mesh is pressed against the surface of the skeletal structure of a living human or animal, characterized by the fact that said mesh material is in the form of a sheet having a thickness in the range of from 1 to 15 millimeters and a porosity in the range of from 80% to 92%, each of the metal fibers in said sheet having a length in the range of from 2 to 50 millimeters, a diameter in the range of from 40 to 100 micrometers, and a length-to-diameter ratio of at least 125, said porous sheet being flexible and deformable by simple hand manipulation without losing its structural integrity. A porous fiber mesh material according to claim 1, wherein said sheet has an apparent modulus of elasticity in the range of from 80 to 100 MPa. A porous fiber mesh material accoring to claim 1 or 2, wherein the metal fibers have been sintered at their points of contact. A porous fiber mesh material according to claims 1-3, wherein the metal fibers are made of cobalt-chromium alloy, titanium, titanium alloy, tantalum, tantalum alloy, stainless steel, niobium or niobium alloy. A porous fiber mesh material according to claim 4, wherein the metal fibers are titanium metal fibers. A porous fiber mesh material according to claims 1-5, which has a porosity such that at least 50% of the pores of the mesh has a pore size of at least 150 micrometers.

Inventors: DUCHEYNE, PAUL
Applicants: DUCHEYNE, PAUL
Application year: 1985
Main classification: A61F2
IPC codes: A61F2, B22F7