Source: http://www.google.co.uk/patents/US7018418
Timestamp: 2014-07-24 19:20:30
Document Index: 523608042

Matched Legal Cases: ['Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60']

Patent US7018418 - Textured surface having undercut micro recesses in a surface - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign in<nobr>Advanced Patent Search</nobr>PatentsTextured surface having micro recesses such that the outer surface overhangs the micro recesses. Embodiments of the textured surface include sharp edges for promoting bone deposition and growth within the micro recesses, protrusions of varying depth from the surface that include overhangs, and micro...http://www.google.co.uk/patents/US7018418?utm_source=gb-gplus-sharePatent US7018418 - Textured surface having undercut micro recesses in a surfaceAdvanced Patent SearchPublication numberUS7018418 B2Publication typeGrantApplication numberUS 10/202,575Publication date28 Mar 2006Filing date24 Jul 2002Priority date25 Jan 2001Fee statusPaidAlso published asCA2470068A1, EP1463630A1, US7850862, US20030065401, US20060129161, WO2003053669A1Publication number10202575, 202575, US 7018418 B2, US 7018418B2, US-B2-7018418, US7018418 B2, US7018418B2InventorsMark Amrich, Jonathan L. Rolfe, Joseph Buturlia, Robert F. LynchOriginal AssigneeTecomet, Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (114), Non-Patent Citations (4), Referenced by (38), Classifications (75), Legal Events (10) External Links: USPTO, USPTO Assignment, EspacenetTextured surface having undercut micro recesses in a surfaceUS 7018418 B2Abstract Textured surface having micro recesses such that the outer surface overhangs the micro recesses. Embodiments of the textured surface include sharp edges for promoting bone deposition and growth within the micro recesses, protrusions of varying depth from the surface that include overhangs, and micro recesses that are at least partially defined by complex ellipsoids.
CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation-in part of U.S. application Ser. No. 09/976,722 filed Oct. 12, 2001, now U.S. Pat. No. 6,599,322 which claims the benefit of U.S. Provisional Application No. 60/264,084 filed, Jan. 25, 2001, and U.S. Provisional Application No. 60/309,923, filed Aug. 3, 2001. This application is also a continuation-in-part of U.S. application Ser. No. 10/021,616, filed Dec. 12, 2001, now U.S. Pat. No. 6,620,332 which claims benefit of U.S. Provisional Application 60/291,022, filed May 15, 2001. This application, furthermore, claims the benefit of priority of U.S. Provisional Application No. 60/340,286, filed Dec. 12, 2001, U.S. Provisional Application No. 60/356,459, filed Feb. 11, 2002, U.S. Provisional Application No. 60/388,033, filed Jun. 12, 2002, and U.S. Provisional Application No. 60/391,957, filed Jun. 25, 2002.
SUMMARY OF THE PREFERRED EMBODIMENTS A preferred embodiment of the invention is a textured surface which is adapted to interlock with an adjacent body and method of producing a textured surface.
FIGS. 6�10 are progressive diagrammatic sectional views showing positioning of the article adjacent a bone and interconnection of the article and the bone;
FIG. 11 is a diagrammatic sectional view of a surgical implant having a plurality of surfaces treated as illustrated in FIGS. 2�10;
FIGS. 15 a�15 c illustrate diagrammatic sectional views off structural features of a textured surface;
FIGS. 17A�17E are three-dimensional illustrations of exemplary textures;
FIGS. 18�27 are diagrammatic cross-sectional views of successive stages in the making of a mesh-and-plate implant in accordance with an embodiment of the invention;
FIG. 28 is a top plan view of a mesh-and-plate implant made in accordance with the method illustrated in FIGS. 18�27;
FIGS. 37A�37C illustrate implants with apertures;
FIGS. 38A�38D illustrate implants with ribs;
FIGS. 39A�39C are diagrammatic cross-sections illustrating textured implants;
DESCRIPTION OF THE PREFERRED EMBODIMENTS Undercutting occurs, for example, when the chemical etchant removes metal beyond the boundary of a maskant, or resist layer. Often, such undercutting limits the fine resolution needed for many processes, such as the production of electronic devices, rotogravure plates, and other fine parts. However, predetermined and controlled undercutting may be exploited and utilized to produce useful and novel three-dimensional geometries by allowing the undercutting effect to expand deeper regions of a chemically applied pattern, so that the resulting treatment layer is an engineered pattern of undercut recesses. This provides sharp geometries when desired, and produces a higher void volume and larger fractal dimensions than are obtainable by other methods. Further, it permits retention of a predetermined area of original surface to afford an engineered and repeatable �datum surface,� or surface intended to abut another body to which the undercut surface will be attached. The metal of the complex pattern is identical and contiguous with the base metal of the treated body, because it is generated in the body, and not later applied, such as the fused metal spheres mentioned hereinabove.
As shown in FIG. 2, a layer 14 of maskant material is deposited on substantially the entirety of the surface 12. The maskant is a suitable acrylic, epoxy, or polyester resist, or the like. The layer 14 may be applied by dipping, spray coating, or electrostatic depositing, or any other coating method to produce a layer thickness of about 0.001�0.010 inch. The coated article of FIG. 2 preferably is baked at 200� F. (�10� F.) for about 15�17 minutes, or any sufficient combination of time, pressure (such as vacuum-baking) and temperature to insure the removal of water, as is customarily used in the art. Kodak Thin Film Resist� has been found to be a quite suitable maskant. To the Kodak Resist is added 2%, by weight, carbon black pigment, or other pigment described hereinbelow.
In one embodiment, the adhesion of the resist or masking agent to a metal surface of the object to be textured preferably includes of an actual chemical, ionic, or molecular bond to the metal itself. In one embodiment, the undercutting process preferably is conducted via spray impingement of the etchant, or other agitation, such as turbulence or ultrasonic cavitation, often for periods of time that are more prolonged than is generally encountered in common photofabrication. The duration of the undercutting process is dependant upon the substrate selected and the etchant system chosen. Preferably, etching lasts up to 10�15 minutes. It may exceed 20 minutes. In some embodiments of the present invention use a layer 14 of common photopolymerized polyester resist, requires cleaning and abrading of the datum surface prior to application of layer 14. As is common good practice in the metal finishing field, in some embodiments, pre-etching and pre-baking of the metal surface is sometimes required to insure the integrity of the maskant-metal bond. In one embodiment, it is desirable to remove a minute amount of surface material (preferably 0.001 inches to 0.005 inches) to insure a chemically clean and pristine metal surface. Additional embodiments include the use of a layer 14 of epoxy dip coatings, electrostatic coatings, electrophoresis coatings or other electro-deposited coatings, and spray coatings of resist or masking agents.
As noted above, a preferred maskant is Kodak Resist, to which is added about 2% carbon black pigment, or other pigment more particularly suited to the laser wavelength to be employed. The pigment is dispersed into the maskant in a high shear mixer until fully dispersed, or until a temperature rise of 15�20� C. is reached. The resulting maskant is applied by dipping or by spraying, spinning, brushing or electrostatically depositing onto the surface to be treated.
An alternative method of manufacture is to use a photo sensitive maskant, which is applied to the device as stated above, or applied as a dry film which is laminated to the surface. The maskant is then exposed, using a light source of an appropriate wavelength (typically 280�550 nanometers). Portions of the maskant are cross-linked and/or bonded to the surface during the exposing process (in the case of negative working resist). The other areas of the maskant are dissolved or washed away in a developing process that utilizes a compatible developer solution, such as sodium or potassium carbonate, or stoddard solvents, thereby exposing the underlying material.
In one embodiment, in a titanium hip joint, for example, the metal was first washed with an alkaline degreasing detergent (e.g., an Oaktite� solution), water-rinsed in de-ionized water and briefly pre-etched in a hydrofluoric/nitric acid etchant solution, so as to produce a chemically clean, freshly-exposed metal surface suited to maskant adhesion, water-rinsed again thoroughly, and oven dried at 110� C. prior to coating with the selected resist agent (e.g., Kodak KPFR, or any other resist, including other polymer classes, such as reactive epoxy or urethan systems, or lacquers and varnishes). A polyester resist coating was then applied by dipping, air-drying for 15 minutes, and baking at 100� C. for 20 minutes. Alternatively, an epoxy e-coating (e.g., PPG Powercron� CF-665) can be successfully used. A desired pattern may then be laser-imaged onto the surface with a 90 watt neodymium-doped YAG laser at 85% power, and at a machine setting of 3 frequency units to achieve a shallow penetration to and below the surface of the base metal. The typical depth of penetration is 10 microns. This assures the cleaning of the metal base layer to remove maskant ablation residues from the regions to be etched. The hip joint was then again baked at 100� C. prior to etching to insure full cross-linking of the polymer, and to remove low-molecular-weight pyrolysis products from the maskant polymer.
In operation, to produce a textured surface on a surgical implant, a selected pattern of undercut and at least in part interconnected recesses is effected in a surface of the surgical implant (FIG. 5). In implantation, the implant surface 12 is pressed against the bone B, (FIG. 6) such that sharp edges 24 of the recesses effect the �scratch fit� with the bone B, which involves shaving off, or milling, particulate segments b of the bone B, which segments b enter the ovoid recesses 20 wherein, in due course, the bone segments b stimulate in-growth of the bone B (FIG. 7) to securely lock the implant to the bone B (FIG. 8).
In some embodiments, a device with a textured surface according to the present invention, can affect a self-fitting function. For example, it will be appreciated that where a textured surface, according to the present invention, is applied to an acetabular cup, the cup itself can be used as a reaming tool, effecting a perfect fit to the host bone and shortening healing time. Further, in the process of self-fitting, there is milled, or harvested, fine bone particulates, or pulp, from the patients' own body, for example, as shown in FIGS. 6�10. The resulting material is forced into the recesses to serve as a nucleation host for a spontaneous homograft completed by the attraction and growth of the patient's osteoblasts, providing a strong bond and longer installed lifetime.
In one embodiment, protrusions 325 are in the form of longitudinal ribs 382 (as illustrated in FIG. 38A and 33) longitudinally disposed on implant 310 such that ribs 382 run generally between proximal end 314 and distal end 312. In one embodiment ribs 382 run generally parallel to axis 311. In another embodiment, angular ribs 383 may be disposed at an angle relative to axis 311, as illustrated in FIG. 38B. In another embodiment, transverse ribs 384 are disposed to form substantially concentric rings that are radially disposed about axis 311 as illustrated in FIG. 38D. Transverse ribs 384 can have any desired pitch angle. In one embodiment, transverse ribs 384 have a low pitch angle. In another embodiment, transverse ribs 384 have a pitch angle of substantially 0�. While longitudinal ribs 382, angular ribs 383, and transverse ribs 384 are shown to be substantially continuous from distal end 312 to proximal end 314, such ribs having discontinuities are also within the scope of the present invention. In one embodiment, ribs 326 may be in the form of discrete segments 335 protruding from wall 320. In one embodiment, discrete segments 335 are evenly distributed about axis 311. In one embodiment evenly spaced discrete segments 335 are of substantially uniform size. In another embodiment, discrete segments 335 are of varying sizes. In another embodiment, discrete segments are unevenly spaced.
N(d)�1/d^Db Eq.(1a)
The information entropy I(d) for a set of N(d) boxes of linear size d is defined as I ⁡ ( d ) = - ∑ i = 1 N ⁡ ( d ) ⁢ ⁢ m i ⁢ log ⁡ ( m i ) ⁢ ⁢ where ⁢ ⁢ m 1 ⁢ ⁢ is ⁢ : Eq . ⁢ (1b) m i = Mi M Eq . ⁢ ( 2 ) where M1 is the number of points in the i-th box and m is the total number of points in the set.
Consider a set of points evenly distributed on the two-dimensional plane. In this case, we will have N ⁡ ( d ) ≈ 1 d 2 ⁢ ⁢ m i ≈ d 2 Eq . ⁢ ( 3 ) so that Eq. (2) can we written as: Eq . ⁢ ( 4 ) ⁢ : ⁢ ⁢ I ⁡ ( d ) ≈ - N ⁡ ( d ) ⁡ [ d 2 ⁢ log ⁡ ( d 2 ) ] ≈ - 1 d 2 ⁡ [ 2 ⁢ d 2 ⁢ log ⁡ ( d ) ] = - 2 ⁢ log ⁡ ( d ) For a set of points composing a smooth line we would find:
It was noted above that the information dimension differs from the box dimension in that it weighs more heavily boxes containing more points. To see this, let us write the number of occupied boxes N(d) and the information entropy I(d), in terms of the masses mi, contained in each box: N ⁡ ( d ) = ∑ i ⁢ m i o ; I ⁡ ( d ) = - ∑ i ⁢ m i ⁢ log ⁡ ( m i ) Eq . ⁢ ( 6 ) The first expression in Eq. (6) is a somewhat elaborate way to write N(d), but it shows that each box counts for one, if mi>0. The second expression is taken directly from the definition of the information entropy Eq. (1b). The number of occupied boxes, N(d), and the information entropy I(d) enter on different ways into the calculation of the respective dimensions, it is clear from [Eq. (6)] that:
Pin Pushout, kN(2)
Cycam 555 surface
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A61F2310/00179, A61F2002/30879, A61F2310/00023, A61F2230/0019, A61F2/32, A61F2/30767, A61F2/446, A61F2002/30777, A61F2/3859, A61F2310/00329, A61F2002/30874, A61B17/8085, A61F2002/30785, A61F2002/30153, A61F2/36, A61C2008/0046, A61F2310/00131, A61F2002/30925, A61F2002/3097, A61F2310/00017, A61F2002/365, A61C8/0012, A61F2310/00029, A61F2002/30838, A61F2310/00089, A61F2002/30892European ClassificationA61F2/30L, A61F2/30L2, B32B3/30, C23F1/02, A61F2/44F2, A61B17/80PLegal EventsDateCodeEventDescription20 Dec 2013ASAssignmentFree format text: SECURITY AGREEMENT;ASSIGNOR:TECOMET INC.;REEL/FRAME:031866/0654Effective date: 20131219Owner name: SOLAR CAPITAL LTD., NEW YORK19 Dec 2013ASAssignmentEffective date: 20131219Owner name: TECOMET INC., MASSACHUSETTSFree format text: RELEASE BY SECURED PARTY;ASSIGNOR:GCI CAPITAL MARKETS LLC, AS ADMINISTRATIVE AGENT;REEL/FRAME:031823/0362Free format text: SECURITY AGREEMENT;ASSIGNOR:TECOMET INC.;REEL/FRAME:031865/0176Owner name: GENERAL ELECTRIC CAPITAL 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