Method of manufacturing synthetic bone coated surgical implants

Claim 2

A process for manufacturing hydroxylapatite-coated implants comprising the steps of: obtaining an implant material suitable for implantation into an animal, ion beam sputter coating said implant material with hydroxylapatite by directing a Xenon ion beam operated at at least 10 kev energy against a hydroxylapatite target positioned such that hydroxylapatite ions kicked off of the target strike the implant material, conducting said ion beam sputter coating under a vacuum of at least 10 -4 torr in the presence of a preselected amount of a molecular oxygen-containing gas, recovering said hydroxylapatite-coated implant annealing said hydroxylapatite-coated implant in a vacuum at a pressure of at least 10 -4 torr from about 1 hour to about 24 hours at a temperature ranging between about 300° C. and about 900° C., and recovering a completely recrystallized hydroxylapatite-coated implant.

Claim 3

The process of claim 1 wherein said metal implant is sputter-etched prior to said ion beam sputter coating.

Claim 4

The process of claim 1 wherein the Xenon ion beam is directed substantially horizontally, the implant material is located below the beam, and the target is positioned in the path of the beam such that HA ions are directed down onto the implant material.

Claim 5

The process of claim 3 wherein the implant material is located on a water cooled rotating platter.

Claim 6

The process of claim 3 wherein said hydroxylapatite target comprises a solid hydroxylapatite coating on a water cooled substrate.

Claim 7

The process of claim 3 wherein said hydroxylapatite target comprises a sintered hydroxylapatite coating on a water cooled substrate.

Claim 8

The process of claim 1 wherein said implant material is selected from the group consisting of titanium, titanium alloys, stainless steel and cobalt-chrome-molybdenum.

Claim 9

The process of claim 7 wherein said hydroxylapatite target comprises powdered hydroxylapatite located on a water cooled tray.

Claim 10

The process of claim 1 wherein said molecular oxygen containing gas is present in amounts such that oxygen present is in the range from about 10 -5 torr to about 10 -6 torr.

Claim 11

The process of claim 1 wherein said molecular oxygen-containing gas comprises water vapor under said vacuum.

Claim 12

The process of claim 10 wherein said molecular oxygen-containing gas is present in amounts such that the oxygen present is in the range from about 10 -5 torr to about 10 -6 torr.

Claim 13

The process of claim 1 wherein the Xenon ion beam is directed substantially horizontally, the implant material is located about the beam, the target is positioned in the path of the beam such that HA ions are directed up onto the implant material.

Claim 14

The process of claim 1, wherein said hyroxylapatite-coated implant is plasma spray coated with a second hydroxylapatite layer.

Claim 15

A hydroxylapatite-coated implant, suitable for implantation into an animal in need of such treatment, manufactured by a process comprising the steps of: obtaining an implant suitable for implantation into an animal, ion beam sputter coated said implant with hydroxylapatite by directing a Xenon ion beam operated at at least 10 kev energy against a hydroxylapatite target positioned such that hydroxylapatite ions kicked off of the target strike the implant, conducting said ion beam sputter coating under a vacuum of at least 10 -5 torr in the presence of a preselected amount of a molecular oxygen containing gas, recovering said hydroxylapatite coated implant, annealing said hydroxylapatite-coated implant in a vacuum at a pressure of at least 10 -4 torr for from about 1 hour to about 24 hours at a temperature ranging between about 300° C. and about 900° C., and recovering said hydroxylapatite-coated implant, the hydroxylapatite coating being fully dense, crystalline and substantially the same in terms of percentages of phosphorous and calcium as natural hydroxylapatite.

Claim 16

A hydroxylapatite-coated implant, suitable for implantation into an animal in need of such treatment, manufactured by a process comprising the steps of: obtaining an implant suitable for implantation into an animal, ion beam sputter coated said implant with hydroxylapatite by directing a Xenon ion beam operated at at least 10 kev energy against a hydroxylapatite target positioned such that hydroxylapatite ions kicked off of the target strike the implant, conducting said ion beam sputter coating under a vacuum of at least 10 -5 torr in the presence of a preselected amount of a molecular oxygen containing gas, recovering said hydroxylapatite coated implant, annealing said hydroxylapatite-coated implant in a vacuum at a pressure of at least 10 -4 torr for from about 1 hour to about 24 hours at a temperature ranging between about 300° C. and about 900° C., and recovering said hydroxylapatite-coated implant, the hydroxylapatite coating being fully dense, crystalline and substantially the same in terms of percentages of phosphorous and calcium as natural hydroxylapatite.

Claim 17

The implant of claim 14 wherein the implant is plasma spray with a second hydroxylapatite layer prior to the step of recovering.