CN107809983A - 植入物和用于涂覆植入物主体的方法 - Google Patents
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Abstract
一种用于植入骨中的植入物(1)尤其是髋臼窝植入物,其至少部分具有包括凸起(3)和凹陷(4)的表面结构(2)。凹陷(4)具有涂覆有多孔涂层(5)的区域。凸起或是根本不涂覆,或是被涂覆成使涂层在这些部分具有较小层厚或较高耐磨性。这样,在植入物被插入骨中时得到改善的耐磨性能。
Description
技术领域
本发明涉及根据独立权利要求的前序部分的用于植入骨中的植入物和用于涂覆植入物主体的方法。
背景技术
已知多种表面结构被用于将植入物尤其是人工假体锚固入骨中。它们的范围从粗糙表面、特殊涂覆到植入物表面带有复杂的结构元件。
因此例如在髋关节假体的情况下有利的是,植入物部分尤其是装到髋骨中的关节窝被不能被扯分开或抗旋转地锚固在骨组织中。虽然使用螺钉来固定多个关节窝,但在其它情况下借助于骨水泥来实现固定,而其它关节窝通过敲入或拧入直接保持在骨中。
为了增强借助骨水泥或经由拧入或敲入而固定的关节窝的防脱出性能和抗扭强度,这种关节窝的表面通常设有粗糙表面结构。因此,一般可通过切削方法在表面中加工出结构元件,这样允许在插入关节窝时和稍后的加载期间产生均匀分布的力,由此防止旋转甚至脱出。在植入物被敲入的情况中,结构元件还使骨能够长到其间隙中。
例如WO2012/126944A1公开了球冠壳形的髋关节窝植入物,其表面结构包括多个结构元件,它们分别由多个具有相反斜率的交叉沟槽形成。
US5,645,593同样描述了一种具有结构元件的骨植入物,但这些结构元件之间的间隙完全被颗粒填充。颗粒形成多孔涂层,这允许通过骨整合实现良好辅助固定。在这种情况下,结构元件的存在防止在将植入物插入骨中时剪切多孔涂层。但由于结构元件之间的凹陷完全被多孔材料填充,故这在插入植入物时削弱了植入物的主要固定并增加了骨头负载。
US4,883,491同样公开了一种人工髋关节窝,但其设有用于拧入骨中的螺纹线。螺纹线被具有多孔涂层的区域中断。但是,多孔涂层在植入物被拧入时未受到免剪切保护。因此,多孔涂层在植入物运输期间或在后者在手术室中进行处理时会被磨损。因此,脱落颗粒可能引起患者身体损伤,而在更糟糕的情况下,脱落颗粒可能进入关节假体的关节面,在那里它们显著增强关节假体损耗。这可能导致整个关节植入物的失效。
发明内容
本发明的目的是要克服现有技术的缺点。
尤其是,本发明的目的提供一种用于植入骨中的改进的植入物,其具有带有多孔涂层的表面结构。在此,该植入物应该能改善在骨中的主要固定,同时具有磨损性能得到改善的表面。
这些目的通过具有权利要求1的特征的植入物以及如权利要求9和11所述的用于涂覆植入物主体的方法来实现。
本发明涉及用于植入骨中的植入物尤其是髋关节窝植入物。该植入物至少部分具有包括凸起和凹陷的表面结构。所述凹陷具有带有多孔涂层的区域。
本发明的特征在于:
a)该凸起具有未涂覆区,该未涂覆区与该凹陷处的涂覆区邻接,
b)或该凸起具有涂覆区,该涂覆区与该凹陷处的涂覆区邻接,其中该凸起处的多孔涂层的层厚度小于该凹陷处的层厚度,
c)或该凸起具有涂覆区,该涂覆区与该凹陷处的涂覆区邻接,其中该凸起处的涂层的孔隙度小于该凹陷处的孔隙度,
d)或该凸起具有涂覆区,该涂覆区与该凹陷处的涂覆区邻接,其中该凸起处的多孔涂层的耐磨性高于该凹陷处的耐磨性。
在这里,多孔涂层贴合凹陷轮廓地延伸。
本文的术语“凸起”和“凹陷”应该彼此相关地来理解。就此而言,术语“耐磨性”指的是多孔涂层对机械负载尤其是摩擦力的抵抗力。它主要由其粗糙度和硬度决定,但也由植入物主体上的粘附强度决定。通过实验,耐磨性比如可通过标准化方法确定,如通过研磨方法或撕裂试验。
多孔涂层不必在整个层厚度范围是多孔的。也可想到某些地方是压实的以形成封闭表面。由于具有低耐磨性或相当大层厚度的涂覆区也仅在表面结构的凹陷区中延伸并因此得到保护,例如在将植入物插入骨中时能显著提高多孔涂层的整体耐磨性能。然而,由于凹陷未完全被多孔材料填充,故植入物仍允许在骨中良好的主要锚固。由于这种原因,多孔涂层总是贴合凹陷轮廓,但这不一定意味着涂层必须是凹陷的精确映像。重要的方面在于具有凹陷和突起的轮廓总是与多孔涂层厚度无关地保持不变。
在植入物情况下,多孔涂层的层厚度可以等于轮廓深度的15%至50%。如果轮廓深度和层厚度之比位于此范围中,则导致了在主要固定和辅助固定之间尤其有利的相互作用。与此相关,术语“轮廓深度”是指在单个凸起的最高点和单个凹陷的最低点之间的平均错移。
在凹陷处,多孔涂层的层厚度可以是0.1毫米至0.5毫米。这样的层厚度允许在骨中良好的辅助固定,确保植入物的机械稳定性。
植入物可包括主体结构,该主体结构由钛、锆、铌、钽或它们的合金、钴铬合金、医用钢、陶瓷或聚乙烯组成。除了医用钢、陶瓷和聚乙烯,多孔涂层也可由这些材料组成。这类材料广泛地用于制造骨植入物。它们可用通用植入物的生产领域的传统方法来加工,并且它们具有与患者的优异相容性。
此外,这类材料可形成用于再生骨细胞的支撑结构,结果是促进自然骨生长。因此,这类材料的使用可辅助植入之后的骨愈合过程并且还可在植入物和骨之间形成稳定连接。在尤其优选的情况下,所述材料甚至可与活的骨组织进行直接的功能性结构结合。这实现了植入物在骨中非常牢固的锚固。
多孔涂层可以是颗粒涂层且尤其可以具有球形的、立方形的或柱形的颗粒。颗粒涂层具有有利的孔隙度。此外,用于将颗粒涂层施加至植入物主体的可靠方法是现有技术已知的,例如大气等离子喷涂方法(APS)或真空等离子喷涂方法(VPS)。通过选择颗粒形状,植入物表面可与相应使用区域相匹配。
可使多孔涂层具有200微米至500微米的平均尺寸颗粒,尤其是粗糙且细小的颗粒。这样的颗粒尺寸提高了孔隙度,这尤其容易适用于骨长入。通过选择颗粒尺寸,植入物表面可匹配于相应用途。
多孔涂层的孔隙度被设置成使得其在所述凹陷的底面处比在所述凸起的侧面区域中或在凸起处更大。
此外,本发明涉及一种用于涂覆植入物主体尤其是用于制造上述植入物的方法,该方法包括以下步骤:
-提供未涂覆的主体,其中所述主体至少部分具有包括凸起和凹陷的表面结构,
-选择性施加多孔涂层,使凹陷区域中的涂覆区邻接凸起区域中的未涂覆区,并且多孔涂层贴合凹陷轮廓地延伸。
这类方法所具有的优势在于,在施加多孔涂层之后不必再次移除它的一部分。
在这种情况下,可通过将层施加在凸起区域中来选择性施加多孔涂层,这防止多孔涂层的粘附。这样的层也可以指掩膜。这种变型代表一种简单方法,其用于在没有使用专用工具情况下选择性地将多孔涂层施加在凹陷区域中。
但也可以想到比如通过设置工艺过程参数例如电子束方向、粒子束焦点或强度来选择性施加多孔涂层。
一种用于涂覆植入物主体尤其是用于制造上述植入物的替代方法,该方法包括以下步骤:
-提供未涂覆的主体,其中所述主体至少部分具有包括凸起和凹陷的表面结构,
-将多孔涂层施加到带有表面结构的区域中,
-在凸起区域中将多孔涂层移除,使得
a)所述凸起具有涂覆区,该涂覆区与凹陷中的涂覆区邻接,并且在凸起处的多孔涂层的层厚度小于在凹陷处的层厚度,
b)或凸起具有涂覆区,该涂覆区与凹陷中的涂覆区邻接,并且在凸起处的多孔涂层的耐磨性高于在凹陷处的耐磨性,
并且多孔涂层贴合凹陷轮廓地延伸。
这种方法代表了一种用于制造上述植入物的尤其简单划算的方法。由于在一个方法步骤中多孔涂层被施加在具有表面结构的区域而没有在凸起的区域和凹陷的区域之间进行区分,所述方法中可采用本领域技术人员极为熟知传统的涂覆方法。
在这种情况下可通过喷砂处理、剪切、刷涂、车削、铣削、磨削、滚磨、化学或电化学移除来除去凸起区域中的多孔涂层。这些技术广泛地经常用于通用植入物的制造领域。
多孔涂层可通过等离子喷涂、尤其是通过大气等离子喷涂方法(APS)或真空等离子喷涂方法(VPS)通过沉积或增材制造来施加。这些方法广泛应用在本领域中,并且根据要满足的要求,允许可靠地、任选选择性地、但在任何情况下都高效地施加多孔涂层。
前述方法可包括附加步骤,其包括烧结涂覆有多孔涂层的主体。这首先实现多孔涂层本身的高强度,其次实现在植入物主体上的良好粘附。
附图说明
从以下对两个实施例的描述和附图中得到本发明的其它优点和具体特征,附图示意性示出:
图1示出本发明植入物的表面结构的横截面轮廓;
图2示出本发明植入物的一替代实施例的表面结构的横截面轮廓;
图3示出用于本发明植入物的未涂覆的植入物主体;
图4示出具有带有根据图1横截面轮廓的表面结构的本发明植入物;
图5示出本发明植入物的表面结构的剖视图;
图6示出本发明植入物的表面结构的放大剖视图。
具体实施方式
从图1可以看出,根据本发明的植入物1的表面结构2包括凸起3和凹陷4。在这里,多孔涂层5的涂覆区6仅在凹陷4范围延伸,而凸起3具有未涂覆区域7a。表面结构2具有轮廓深度t,并且在涂覆区6的多孔涂层5具有层厚度d。
如从图2所看到地,在此所示的实施例与图1所示的实施例的不同之处在于凸起3和凹陷4都涂覆有多孔涂层5。但凸起3具有涂覆区7b,其中多孔涂层5的层厚度小于凹陷4中的层厚度。但是,这里的涂层也可单纯地具有比在凹陷4中更小的孔隙度或更大的紧密性。因此,在区域7b处的多孔涂层5的耐磨性高于在凹陷4处的耐磨性。所示的多孔涂层5是由颗粒9组成的颗粒涂层。
根据图3的植入物主体8通过在金属坯上制出槽形凹陷4制成。这是球冠壳形植入物主体8,其具有极点10和赤道部11。除了已经提及的凹陷4外,表面结构2还具有凸起3。
图4所示的本发明的植入物1是由图3所示类型的主体8制成的,在此使用了根据权利要求11的方法。相应地,在提供未涂覆的主体8之后,将多孔涂层5施加至具有表面结构的区域,在这种情况下,其从极点10延伸至赤道部11。随后,凸起3区域中的多孔涂层5被再次移除,使得在凸起3处的多孔涂层5的层厚度小于在凹陷4处的层厚度。材料移除去除了附着性较小的颗粒,而这导致层厚减小。结果,在凸起3处的多孔涂层5的耐磨性高于在凹陷4处的耐磨性。
图5和图6示出本发明植入物的表面结构的剖视图。
如图5所示,凸起3在横截面中是非对称设计的。由钛颗粒构成的涂层5在急降的左侧和略平缓的右侧具有不同的分布。涂层的暗区对应于亮的钛颗粒之间的孔。清楚可见的是在凹陷4处的层厚度大于在凸起3顶点处的层厚度。
图6相比于图5进一步放大的示出了涂层5的开孔型结构。钛颗粒的亮区形成了允许骨质长入的裂缝结构。
Claims (14)
1.一种用于植入骨中的植入物(1)尤其是髋关节窝植入物,其中所述植入物(1)至少部分具有包括凸起(3)和凹陷(4)的表面结构(2),其中所述凹陷(4)具有带有多孔涂层(5)的区域(6),其特征在于,
a)该凸起(3)具有未涂覆区(7),该未涂覆区与该凹陷处的涂覆区(6)邻接,
b)或该凸起(3)具有涂覆区(7),该涂覆区与该凹陷处的涂覆区(6)邻接,其中在该凸起处的该多孔涂层(5)的层厚度小于在该凹陷(4)处的层厚度,
c)或该凸起具有涂覆区,该涂覆区与该凹陷处的涂覆区邻接,其中在该凸起处的该涂层的孔隙度小于在该凹陷处的孔隙度,
d)或该凸起(3)具有涂覆区(7),该涂覆区与该凹陷处的涂覆区(6)邻接,其中在该凸起(3)处的该多孔涂层(5)的耐磨性高于在该凹陷(4)处的耐磨性,
并且该多孔涂层(5)贴合该凹陷轮廓地延伸。
2.如权利要求1所述的植入物(1),其特征在于,所述凹陷(4)处的所述多孔涂层(5)的所述层厚度(d)等于轮廓深度(t)的15%至50%。
3.如权利要求1或2所述的植入物(1),其特征在于,所述凹陷(4)处的所述多孔涂层(5)的所述层厚度(d)在0.2毫米至0.5毫米之间。
4.如权利要求1至3之一所述的植入物(1),其特征在于,所述植入物(1)包括主体(8),该主体由钛、锆、铌、钽或它们的合金、钴铬合金、医用钢、陶瓷或聚乙烯组成。
5.如权利要求1至4之一所述的植入物(1),其特征在于,所述植入物(1)具有多孔涂层(5),该多孔涂层由钛、锆、铌、钽或它们的合金、钴铬合金组成。
6.如权利要求1至5之一所述的植入物(1),其特征在于,所述多孔涂层(5)是颗粒涂层且尤其具有球形的、立方形的、柱形的颗粒(9)。
7.如权利要求6所述的植入物(1),其特征在于,所述多孔涂层(5)具有平均尺寸在200微米至500微米之间的颗粒(9)。
8.如权利要求1至7之一所述的植入物(1),其特征在于,所述涂层的孔隙度被设置成使得其在所述凹陷(4)的底面处比在所述凸起(3)的侧面区域中或在所述凸起处更大。
9.一种用于涂覆植入物主体(8)、尤其是用于制造如权利要求1至8之一所述的植入物(1)的方法,所述方法包括以下步骤:
-提供未涂覆的主体(8),其中所述主体(8)至少部分具有包括凸起(3)和凹陷(4)的表面结构(2),
-选择性施加多孔涂层(5),使得所述凹陷(4)的区域中的涂覆区(6)邻接所述凸起(3)的区域中的未涂覆区(7),并使得所述多孔涂层(5)贴合所述凹陷(4)轮廓地延伸。
10.如权利要求9所述的方法,其特征在于,通过将层施加至所述凸起(3)的区域中来选择性施加所述多孔涂层(5),该层最大程度地防止所述多孔涂层(5)粘附。
11.一种用于涂覆植入物主体(8)尤其是用于制造如权利要求1至8之一所述的植入物(1)的方法,所述方法包括以下步骤:
-提供未涂覆的主体(8),其中所述主体(8)至少部分地具有包括凸起(3)和凹陷(4)的表面结构(2),
-将多孔涂层(5)施加到带有所述表面结构(2)的区域,
-在所述凸起(3)的区域中将所述多孔涂层(5)移除,使得
a)所述凸起具有涂覆区(7),该涂覆区与所述凹陷中的所述涂覆区(6)邻接,其中在所述凸起处的所述多孔涂层的层厚度小于在所述凹陷(4)处的层厚度,
b)或所述凸起(3)具有涂覆区(7),该涂覆区与所述凹陷处的所述涂覆区(6)邻接,并且在所述凸起处的所述多孔涂层(5)的耐磨性高于在所述凹陷(4)处的耐磨性,
c)或所述凸起具有涂覆区,该涂覆区与所述凹陷处的所述涂覆区邻接,其中在所述凸起处的所述涂层的孔隙度小于在所述凹陷处的孔隙度,
并且使得所述多孔涂层(5)贴合所述凹陷(4)轮廓地延伸。
12.如权利要求11所述的方法,其特征在于,通过喷砂处理、剪切、刷涂、车削、铣削、磨削、滚磨、化学或电化学移除进行所述凸起(3)的区域中的所述多孔涂层(5)去除。
13.如权利要求9至12之一所述的方法,其特征在于,所述多孔涂层(5)的施加通过等离子喷涂、尤其通过大气等离子喷涂方法(APS)或真空等离子喷涂方法(VPS)通过沉积或增材制造进行。
14.如权利要求9至13之一所述的方法,其特征在于,所述方法另外包括以下步骤:烧结涂覆有所述多孔涂层(5)的所述主体(8)。
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PCT/EP2016/058549 WO2017001078A1 (de) | 2015-06-30 | 2016-04-18 | Implantat und verfahren zum beschichten eines implantatgrundkörpers |
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WO2018026449A1 (en) | 2016-08-03 | 2018-02-08 | Titan Spine, Llc | Implant surfaces that enhance osteoinduction |
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