US6527810B2
Expired / Lapsed
US
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Bone substitutes
Assignee: Wright Medical Technology Inc
•
Filing: 2000-12-21
•
Granted: 2003-03-04
•
Expires: 2020-12-21
Abstract
Abstract A strong, porous article useful as a bone substitute material. The article comprises a continuous strong framework structure having struts defining interstices which interconnect throughout the bulk volume, and may have ceramic or osteoconductive material occupying at least a portion of the same bulk volume as the framework structure. Either as a coating on the strong framework struts or between the framework struts and the ceramic or osteoconductive-osteoinductive materials is a resilient material which serves to distribute stresses within the article.
Inventors
- 👤 James R. Johnson
- 👤 Jeffrey G. Marx
- 👤 Wesley D. Johnson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 22:00
CPC Classifications
A; A61; A61F; A61F2/00; A61F2/02; A61F2/28; A61F2/30; A61F2/30767; A61L; A61L27/00; A61L27/40; A61L27/42; A61L27/425; A61L27/427; A61L27/50; A61L27/56; A61F2/32; A61F2/36; A61F2/3662; A61F2/367; A61F2/38; A61F2/389; A61F2002/2817; A61F2002/30001; A61F2002/30003; A61F2002/3006; A61F2002/30092; A61F2/30771; A61F2002/30878; A61F2002/30884; A61F2/3094; A61F2002/30968; A61F2210/00; A61F2210/0014; A61F2310/00; A61F2310/00005; A61F2310/00011; A61F2310/00017; A61F2310/00023; A61F2310/00029; A61F2310/00035; A61F2310/00131; A61F2310/00179; A61F2310/00185; A61F2310/00203; A61F2310/00239; A61F2310/00293; A61L2400/00; A61L2400/18; A61L2430/00; A61L2430/02
Claims Analysis
Total Claims: 41
Claim 1
Independent Claim
110 words
A method for producing a strong, porous article useful as a bone substitute material comprising a continuous strong supportive sintered, load-bearing framework having struts defining a plurality of interconnecting interstices having 3—3 connectivity, and a resilient coating within said interstices and encasing said struts to provide residual strength to the struts and retain mechanical integrity of the article upon strut failure, wherein said resilient coating comprises a bioresorbable polymer and wherein said method comprises, providing the continuous strong supportive sintered, load-bearing framework having struts defining a plurality of interconnecting interstices having 3—3 connectivity; and contacting the framework with the bioresorbable polymer whereby said struts are encased with the bioresorbable polymer.
Claim 2
Independent Claim
110 words
A method for producing a strong, porous article useful as a bone substitute material comprising a continuous strong supportive sintered, load-bearing framework having struts defining a plurality of interconnecting interstices having 3—3 connectivity, and a resilient coating within said interstices and encasing said struts to provide residual strength to the struts and retain mechanical integrity of the article upon strut failure, wherein said resilient coating comprises a bioresorbable polymer and wherein said method comprises, providing the continuous strong supportive sintered, load-bearing framework having struts defining a plurality of interconnecting interstices having 3—3 connectivity; and contacting the framework with the bioresorbable polymer whereby said struts are encased with the bioresorbable polymer.
Claim 3
Dependent Claim
20 words
A method according to claim 1 , wherein the sintered, load-bearing framework comprises a composite of zirconia and calcium phosphate.
Claim 4
Dependent Claim
15 words
A method according to claim 1 , wherein the sintered, load-bearing framework comprises a ceramic.
Claim 5
Dependent Claim
20 words
A method according to claim 3 , wherein the sintered, load-bearing framework comprises one or more of alumina and zirconia.
Claim 6
Dependent Claim
15 words
A method according to claim 1 , wherein the sintered, load-bearing framework comprises a metal.
Claim 7
Dependent Claim
15 words
A method according to claim 5 , wherein the sintered, load-bearing framework comprises stainless steel.
Claim 8
Dependent Claim
38 words
A method according to claim 1 , wherein the bioresorbable polymer comprises a polymer selected from the group consisting of collagen, chitosan, chitin, poly(glycolic acid), poly (lactic acid), a copolymer of glycolic and lactic acid and mixtures thereof.
Claim 9
Dependent Claim
26 words
A method according to claim 1 , wherein the bioresorbable polymer comprises a polymer selected from the group consisting of collagen, chitosan, chitin and mixtures thereof.
Claim 10
Dependent Claim
65 words
A method according to claim 1 , wherein the step of providing the continuous strong supportive sintered, load-bearing framework further comprises: providing a reticulated foam; providing a slip of a ceramic or metal; contacting the reticulated foam with the slip; removing any excess slip; drying to remove slip solvent; and heating to a temperature sufficient to remove the reticulated foam and to sinter the framework.
Claim 11
Dependent Claim
30 words
A method according to claim 1 , wherein the step of contacting the framework with the bioresorbable polymer further comprises coating the bioresorbable polymer on the struts of the framework.
Claim 12
Dependent Claim
26 words
A method according to claim 10 , wherein the step of coating the bioresorbable polymer on the struts of the framework completely fills the interconnecting interstices.
Claim 13
Dependent Claim
16 words
A method according to claim 11 , wherein the bioresorbable polymer includes a particulate osteoconductive material.
Claim 14
Dependent Claim
20 words
A method according to claim 1 , wherein the interconnecting interstices have an opening ranging from 50 to 1000 μm.
Claim 15
Dependent Claim
20 words
A method according to claim 1 , wherein the interconnecting interstices have an opening ranging from 200 to 600 μm.
Claim 16
Independent Claim
179 words
A method of producing a strong, porous article useful as a bone substitute material comprising a continuous strong supportive sintered, load-bearing framework having struts defining a plurality of interconnecting interstices having 3—3 connectivity, a resilient coating within said interstices and encasing said struts to provide residual strength to the struts and retain mechanical integrity of the article upon strut failure, and an osteoconductive material contained within said interstices but separated from said struts by the resilient coating encasing said struts, wherein said method comprises, comprising: providing a reticulated foam; providing a slip of a ceramic or metal; contacting the reticulated foam with the slip; removing any excess slip; drying to remove slip solvent; and heating to a temperature sufficient to remove the reticulate foam and to sinter the framework to provide the continuous strong supportive sintered, load-bearing first framework having struts defining a plurality of interconnecting interstices; providing within said interstices but spaced apart from said struts a solid osteoconductive material; and providing a resilient interlayer between and at least partially separating said framework and said solid osteoconductive material.
Claim 17
Independent Claim
179 words
A method of producing a strong, porous article useful as a bone substitute material comprising a continuous strong supportive sintered, load-bearing framework having struts defining a plurality of interconnecting interstices having 3—3 connectivity, a resilient coating within said interstices and encasing said struts to provide residual strength to the struts and retain mechanical integrity of the article upon strut failure, and an osteoconductive material contained within said interstices but separated from said struts by the resilient coating encasing said struts, wherein said method comprises, comprising: providing a reticulated foam; providing a slip of a ceramic or metal; contacting the reticulated foam with the slip; removing any excess slip; drying to remove slip solvent; and heating to a temperature sufficient to remove the reticulate foam and to sinter the framework to provide the continuous strong supportive sintered, load-bearing first framework having struts defining a plurality of interconnecting interstices; providing within said interstices but spaced apart from said struts a solid osteoconductive material; and providing a resilient interlayer between and at least partially separating said framework and said solid osteoconductive material.
Claim 18
Dependent Claim
58 words
A method as claimed in claim 15 , wherein the step providing the osteoconductive material comprises: providing a second rigid framework of an osteoconductive material contained within said interstices but spaced from said struts, and the step of providing a resilient material comprises providing said resilient interlayer between and at least partially separating said first and second frameworks.
Claim 19
Dependent Claim
62 words
A method as claimed in claim 16 , wherein the step of providing the osteoconductive material further comprises: filling interstices of the sintered, load-bearing first framework with an osteoconductive material containing an organic binder; and heating the osteoconductive material, whereby the osteoconductive material shrinks and forms an intervening space between the struts forming the first framework and the osteoconductive material second framework.
Claim 20
Dependent Claim
37 words
A method as claimed in claim 17 , wherein the step of providing the osteoconductive material further comprises coating the struts of the first framework with a release agent before filling the interstices with the osteoconductive material.
Claim 21
Dependent Claim
15 words
A method as claimed in claim 18 , wherein the release agent comprises a wax.
Claim 22
Dependent Claim
20 words
A method according to claim 15 , wherein the sintered, load-bearing framework comprises a composite of zirconia and calcium phosphate.
Claim 23
Dependent Claim
15 words
A method according to claim 15 , wherein the sintered, load-bearing framework comprises a ceramic.
Claim 24
Dependent Claim
20 words
A method according to claim 21 , wherein the sintered, load-bearing framework comprises one or more of alumina and zirconia.
Claim 25
Dependent Claim
38 words
A method according to claim 15 , wherein the bioresorbable polymer comprises a polymer selected from the group consisting of collagen, chistosan, chitin, poly(glycolic acid), poly (lactic acid), a copolymer of glycolic and lactic acid and mixtures thereof.
Claim 26
Dependent Claim
20 words
A method according to claim 15 , wherein the interconnecting interstices have an opening ranging from 50 to 1000 μm.
Claim 27
Dependent Claim
20 words
A method according to claim 15 , wherein the interconnecting interstices have an opening ranging from 200 to 600 μm.
Claim 28
Independent Claim
138 words
A method of producing a strong, porous article useful as a bone substitute material comprising a continuous strong supportive sintered, load-bearing framework having struts defining a plurality of interconnecting interstices, an osteoconductive material contained within said interstices but separate from said struts, and a resilient material that completely fills the spaces between the struts and the osteoconductive material to provide residual strength to the struts and osteoconductive material retain mechanical integrity of the article upon strut failure, wherein the osteoconductive material is a continuous interconnected body, and wherein said method comprises: providing a continuous strong supportive sintered load-bearing framework having struts defining a plurality of interconnecting interstices; providing within said interstices but spaced from said struts, a solid osteoconductive material; and providing a resilient interlayer between and at least partially separating said framework and said solid osteoconductive material.
Claim 29
Independent Claim
138 words
A method of producing a strong, porous article useful as a bone substitute material comprising a continuous strong supportive sintered, load-bearing framework having struts defining a plurality of interconnecting interstices, an osteoconductive material contained within said interstices but separate from said struts, and a resilient material that completely fills the spaces between the struts and the osteoconductive material to provide residual strength to the struts and osteoconductive material retain mechanical integrity of the article upon strut failure, wherein the osteoconductive material is a continuous interconnected body, and wherein said method comprises: providing a continuous strong supportive sintered load-bearing framework having struts defining a plurality of interconnecting interstices; providing within said interstices but spaced from said struts, a solid osteoconductive material; and providing a resilient interlayer between and at least partially separating said framework and said solid osteoconductive material.
Claim 30
Dependent Claim
20 words
A method according to claim 26 , wherein the sintered, load-bearing framework comprises a composite of zirconia and calcium phosphate.
Claim 31
Dependent Claim
15 words
A method according to claim 26 , wherein the sintered, load-bearing framework comprises a ceramic.
Claim 32
Dependent Claim
20 words
A method according to claim 28 , wherein the sintered, load-bearing framework comprises one or more of alumina and zirconia.
Claim 33
Dependent Claim
38 words
A method according to claim 26 , wherein the bioresorbable polymer comprises a polymer selected from the group consisting of collagen, chitosan, chitin, poly(glycolic acid), poly (lactic acid), a copolymer of glycolic and lactic acid and mixtures thereof.
Claim 34
Dependent Claim
20 words
A method according to claim 26 , wherein the interconnecting interstices have an opening ranging from 50 to 1000 μm.
Claim 35
Dependent Claim
20 words
A method according to claim 26 , wherein the interconnecting interstices have an opening ranging from 200 to 600 μm.
Claim 36
Independent Claim
82 words
A method of producing a strong, porous article useful as a bone substitute material comprising a continuous strong supportive sintered, load-bearing ceramic framework having struts defining a plurality of interconnecting interstices having 3—3 connectivity wherein said method comprises: providing a reticulated foam; providing a slip of a ceramic or metal; contacting the reticulated foam with the slip; removing any excess slip; drying to remove slip solvent; and heating to a temperature sufficient to remove the reticulated foam and to sinter the framework.
Claim 37
Independent Claim
82 words
A method of producing a strong, porous article useful as a bone substitute material comprising a continuous strong supportive sintered, load-bearing ceramic framework having struts defining a plurality of interconnecting interstices having 3—3 connectivity wherein said method comprises: providing a reticulated foam; providing a slip of a ceramic or metal; contacting the reticulated foam with the slip; removing any excess slip; drying to remove slip solvent; and heating to a temperature sufficient to remove the reticulated foam and to sinter the framework.
Claim 38
Dependent Claim
23 words
A method according to claim 33 , wherein the sintered, load-bearing ceramic framework comprises one or more of alumina, zirconia and calcium phosphate.
Claim 39
Dependent Claim
30 words
A strong, porous article useful as a bone substitute material comprising a continuous strong supportive sintered, load-bearing ceramic framework having struts defining a plurality of interconnecting interstices having 3—3 connectivity.
Claim 40
Dependent Claim
30 words
A strong, porous article useful as a bone substitute material comprising a continuous strong supportive sintered, load-bearing ceramic framework having struts defining a plurality of interconnecting interstices having 3—3 connectivity.
Claim 41
Dependent Claim
23 words
An article according to claim 35 , wherein the sintered, load-bearing ceramic framework comprises one or more of alumina, zirconia and calcium phosphate.
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