CA2431736A1 - A method for attaching a porous metal layer to a metal substrate - Google Patents

A method for attaching a porous metal layer to a metal substrate Download PDF

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Publication number
CA2431736A1
CA2431736A1 CA002431736A CA2431736A CA2431736A1 CA 2431736 A1 CA2431736 A1 CA 2431736A1 CA 002431736 A CA002431736 A CA 002431736A CA 2431736 A CA2431736 A CA 2431736A CA 2431736 A1 CA2431736 A1 CA 2431736A1
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Canada
Prior art keywords
metal
porous
substrate
binding mixture
assembly
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Granted
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CA002431736A
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French (fr)
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CA2431736C (en
Inventor
Dana Medlin
Steven J. Charlebois
William B. Clarke
Dirk Pletcher
Joel G. Scrafton
H. Ravindranath Shetty
Dale Swarts
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Zimmer Technology Inc
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Individual
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Priority to CA 2775689 priority Critical patent/CA2775689C/en
Publication of CA2431736A1 publication Critical patent/CA2431736A1/en
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C26/00—Coating not provided for in groups C23C2/00 - C23C24/00
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
    • A61F2/30—Joints
    • A61F2/30767—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
    • A61F2/30—Joints
    • A61F2/30767—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
    • A61F2/30907—Nets or sleeves applied to surface of prostheses or in cement
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/02—Inorganic materials
    • A61L27/04—Metals or alloys
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/28—Materials for coating prostheses
    • A61L27/30—Inorganic materials
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/50—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L27/56—Porous materials, e.g. foams or sponges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
    • B22F7/004—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • B22F7/064—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts using an intermediate powder layer
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
    • A61F2/30—Joints
    • A61F2/3094—Designing or manufacturing processes
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
    • A61F2/30—Joints
    • A61F2/38—Joints for elbows or knees
    • A61F2/3859—Femoral components
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
    • A61F2/30—Joints
    • A61F2/30767—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
    • A61F2/30771—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth applied in original prostheses, e.g. holes or grooves
    • A61F2002/30772—Apertures or holes, e.g. of circular cross section
    • A61F2002/30784—Plurality of holes
    • A61F2002/30787—Plurality of holes inclined obliquely with respect to each other
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
    • A61F2/30—Joints
    • A61F2/3094—Designing or manufacturing processes
    • A61F2002/30967—Diffusion bonding
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
    • A61F2/30—Joints
    • A61F2/3094—Designing or manufacturing processes
    • A61F2002/30968—Sintering
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
    • A61F2/30—Joints
    • A61F2/3094—Designing or manufacturing processes
    • A61F2002/30978—Designing or manufacturing processes using electrical discharge machining [EDM]
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
    • A61F2/30—Joints
    • A61F2/32—Joints for the hip
    • A61F2/34—Acetabular cups
    • A61F2002/3401—Acetabular cups with radial apertures, e.g. radial bores for receiving fixation screws
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2310/00—Prostheses classified in A61F2/28 or A61F2/30 - A61F2/44 being constructed from or coated with a particular material
    • A61F2310/00005—The prosthesis being constructed from a particular material
    • A61F2310/00011—Metals or alloys
    • A61F2310/00023—Titanium or titanium-based alloys, e.g. Ti-Ni alloys
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2310/00—Prostheses classified in A61F2/28 or A61F2/30 - A61F2/44 being constructed from or coated with a particular material
    • A61F2310/00005—The prosthesis being constructed from a particular material
    • A61F2310/00011—Metals or alloys
    • A61F2310/00029—Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2310/00—Prostheses classified in A61F2/28 or A61F2/30 - A61F2/44 being constructed from or coated with a particular material
    • A61F2310/00389—The prosthesis being coated or covered with a particular material
    • A61F2310/00395—Coating or prosthesis-covering structure made of metals or of alloys
    • A61F2310/00407—Coating made of titanium or of Ti-based alloys
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2310/00—Prostheses classified in A61F2/28 or A61F2/30 - A61F2/44 being constructed from or coated with a particular material
    • A61F2310/00389—The prosthesis being coated or covered with a particular material
    • A61F2310/00395—Coating or prosthesis-covering structure made of metals or of alloys
    • A61F2310/00419—Other metals
    • A61F2310/00544—Coating made of tantalum or Ta-based alloys

Abstract

A method for attaching a porous metal layer to a dense metal substrate, wherein the method is particularly useful in forming orthopedic implants such as femoral knee components or acetabular cups. The method, in one embodiment thereof, comprises providing a structured porous layer; providing a dense metal substrate;
providing a binding mixture; applying the binding mixture to the exterior of the substrate; placing the porous layer against the substrate such that the binding mixture is disposed there between forming an assembly; and heat treating the assembly to metallurgically bond the porous layer to the substrate.

Claims (42)

1. A method for attaching a porous metal structure to a metal substrate, the method comprising:
providing a metal substrate;
providing a binding mixture;
providing the porous metal structure;
applying the binding mixture to the porous structure by means selected from the group consisting of spraying, and dipping;
placing the porous structure against the substrate such that the binding mixture is disposed between the metal component and the porous structure, thereby forming an assembly; and heating the assembly to metallugically bond the porous structure and the substrate.
2. The method of claim 1, wherein the metal substrate comprises a metal selected from the group consisting of cobalt, cobalt alloy, titanium and titanium alloy.
3. The method of claim 1, wherein the binding mixture comprises a suspending additive selected from the group consisting of gelatin, glycerin, PVA and water, and wherein the binding mixture further comprises a powdered metal.
4. The method of claim 3, wherein the metal powder is selected from the group consisting of cobalt, cobalt alloy, hafnium, molybdenum, palladium, niobium, zirconium, zirconium alloy, titanium, and titanium alloy.
5. The method of claim 4, wherein the binding mixture comprises above about 10%
by volume powdered metal.
6. The method of claim 4, wherein the binding mixture comprises above about 30%
by volume powder.
7. The method of claim 4, wherein the binding mixture comprises above about 68%
by volume powdered metal.
8. The method of claim 4, wherein the binding mixture comprises about 95% by volume powdered metal.
9. The method of claim 1, wherein the heating step comprises: heating the assembly at about 100°C to 600°C for about 1 to 4 hours; and further heating the assembly at about 800°C to 1600°C for about 1 hour to about 4 hours.
10. The method of claim 9, wherein the heating step is performed in an inert environment comprising a gas selected from the group consisting of argon and helium.
11. The method of claim 9, wherein the heating step is performed in an at least partial vacuum.
12. A method for attaching a porous metal structure to a metal substrate, the method comprising:
providing a metal substrate;
providing a binding mixture;
providing the porous metal structure;
applying the binding mixture to the porous structure by means selected from the group consisting of spraying, and dipping;
placing the porous structure against the substrate such that the binding mixture is disposed between the metal component and the porous structure, thereby forming an assembly; and applying heat and pressure to the assembly to metallugically bond the porous structure and the substrate.
13. The method of claim 12, wherein the metal substrate comprises a metal selected from the group consisting of cobalt, cobalt alloys, titanium and titanium alloys.
14. The method of claim 12, wherein the binding mixture comprises a suspending additive selected from the group consisting of gelatin, glycerin, PVA and water, and wherein the binding mixture further comprises a powdered metal.
15. The method of claim 14, wherein the powdered metal is selected from the group consisting of cobalt, cobalt alloy, hafnium, molybdenum, palladium, niobium, zirconium.
zirconium alloy, titanium, and titanium alloy.
16. The method of claim 15, wherein the binding mixture comprises above about 10%
by volume powdered metal.
17. The method of claim 15, wherein the binding mixture comprises above about 30%
by volume powdered metal.
18. The method of claim 15, wherein the binding mixture comprises above about 68%
by volume powdered metal.
19. The method of claim 15, wherein the binding mixture comprises about 95% by volume powdered metal.
20. The method of claim 12, wherein the step of applying heat and pressure comprises:
heating the assembly to about 800°C to 1600°C for about 1 hour to about 4 hours, at a clamping pressure of between about 200 p.s.i. and 1200 p.s.i..
21. The method of claim 20, wherein the step of applying heat and pressure is performed in an inert environment comprising a gas selected from the group consisting of argon and helium.
22. The method of claim 20, wherein the step of applying heat and pressure is performed in an at least partial vacuum.
23. A method for attaching a porous metal structure to a metal substrate, the method comprising:
providing a metal substrate;
providing the porous metal structure;
contouring a surface of the porous metal structure;
placing the porous structure against the substrate such that the contoured surface of the porous structure is in contact with the substrate, thereby forming an assembly; and heating the assembly to metallugically bond the porous structure and the substrate.
24. The method of claim 23, wherein the metal substrate comprises a metal selected from the group consisting of cobalt, cobalt alloys, titanium and titanium alloys.
25. The method of claim 23, wherein the contouring step comprises machining the surface of the porous metal structure.
26, The method of claim 23, wherein the contouring step comprises. electro-discharge machining the surface of the porous metal structure.
27. The method of claim 23, wherein the heating step comprises: heating the assembly at about 100°C to 600°C for about 1 to 4 hours; and further heating the assembly at about 800°C to 1600°C for about one hour to about four hours.
28. The method of claim 23, wherein the heating step is performed in an inert environment comprising a gas selected from the group consisting of argon and helium.
29. The method of claim 23, wherein the heating step is performed in an at least partial vacuum.
30. A method for attaching a porous metal structure to a metal substrate, the method comprising:
providing a metal substrate;
providing the porous metal structure;
contouring a surface of the porous metal structure;
placing the porous structure against the substrate such that the contoured surface of the porous metal structure is disposed against the substrate, thereby forming an assembly; and applying heat and pressure to the assembly to metallugically bond the porous structure and the substrate.
31. The method of claim 30, wherein the metal substrate comprises a metal selected from the group consisting of cobalt, cobalt alloys, titanium and titanium alloys.
32. The method of claim 30, wherein the contouring step comprises machining the surface of the porous metal structure.
33, The method of claim 30, wherein the contouring step comprises electro-discharge machining the surface of the porous metal structure.
34. The method of claim 30, wherein the heating step comprises: heating the assembly to about 800°C to 1600°C for about one hour to about four hours, under a clamping pressure of between about 200 p.s.i. and about 1200 p.s.i.
35. The method of claim 30, wherein the step of applying heat and pressure is in an inert environment comprising a gas selected from the group consisting of argon and helium.
36. The method of claim 30, Wherein the step of applying heat and pressure is performed in an at least partial vacuum.
37. A method for attaching a porous metal structure to a metal component of an orthopedic implant, the method comprising:
providing a metal component, having a desired shape and a bone contacting surface;
providing a binding mixture;

providing the porous metal structure in a desired shape;
applying the binding mixture to the porous structure by means selected from the group consisting of spraying, and dipping;
placing the porous structure against the bone contacting surface of the metal component such that the binding mixture is disposed between the metal component and the porous structure, thereby forming an assembly; and heating the assembly to metallugically bond the porous structure and the metal component.
38. A method for attaching a porous metal structure to a metal component of an orthopedic implant, the method comprising:
providing a metal component, having a desired shape and a bone contacting surface;
providing a binding mixture;
providing the porous metal structure in a desired shape;
applying the binding mixture to the porous structure by means selected from the group consisting of spraying, and dipping;
placing the porous structure against the bone contacting surface of the metal component such that the binding mixture is disposed between the metal component and the porous metal structure, thereby forming an assembly; and applying heat and pressure to the assembly to metallugically bond the porous structure and the metal component.
39. A method fox attaching a porous metal structure to a metal component of an orthopedic implant, the method comprising:
providing a metal component, having a desired shape and a. bone contacting surface;
providing the porous metal structure in a desired shape;
contouring a surface of the porous metal structure;
placing the porous structure against the bone contacting surface of the metal component such that the contoured surface of the porous structure is in contact with the metal component, thereby forming an assembly; and heating the assembly to metallugically bond the porous structure and the substrate.
40. A method for attaching a porous metal structure to a metal component of an orthopedic implant, the method comprising:
providing a metal component, having a desired shape and a bone contacting surface;
providing the porous metal structure in a desired shape;
contouring a surface of the porous metal structure;
placing the porous structure against the bone contacting surface of the metal component such that the contoured surface of the porous structure is in contact with the metal component, thereby forming an assembly; and applying heat and pressure to the assembly to metallugically bond the porous structure and the substrate.
41. The method of any one of Claims 1-22, 37 or 38, wherein the step of applying the binding mixture comprises applying the binding mixture to the metal substrate but not to the porous metal layer.
42. The method of any one of Claims 1-22, 37 or 38, wherein the step of applying the binding mixture comprises applying the binding mixture to the metal substrate and to the porous metal layer.
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CA2431736C (en) 2012-08-07
US20030232124A1 (en) 2003-12-18
JP2004041726A (en) 2004-02-12
AU2003204797B8 (en) 2009-12-24
JP4444587B2 (en) 2010-03-31
AU2003204797B2 (en) 2009-08-27
EP1398045A1 (en) 2004-03-17
AU2003204797A1 (en) 2004-01-15
CA2775689A1 (en) 2003-12-18
US6945448B2 (en) 2005-09-20
CA2775689C (en) 2015-03-31
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US20050242162A1 (en) 2005-11-03

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