IMPLANT WITH ENHANCED OSTEOINDUCTIVITY

Abstract

An implant device configured to be at least partially in contact with bone on implantation has an improved osteoinductive feature to enhance new bone formation. The implant device has one or more bone growth surfaces extending from a structurally solid feature of the implant device. The one or more bone growth surfaces are configured to mimic adult trabecular bone by having trenches, grooves or surface recesses or prominences exhibiting numerous structural elements or walls not perpendicular to the surface that are non-coplanar or arched extending 20 to 500 microns in depth having an increasing inclination from the surface extending inwardly and not parallel to opposing or adjacent walls forming a random or non-random network. The one or more bone growth surfaces configured to mimic trabecular bone have discernable nano features on the structural elements or walls exhibiting nano scale features of less than 200 nano meters within the network.

Claims

1. A method of providing enhanced bone growth surfaces on an implant device comprises the steps of: providing an implant device; and laser etching one or more surfaces of the implant device to create bone growth surfaces configured to mimic adult trabecular bone by having trenches, grooves or surface recesses or prominences exhibiting numerous structural elements or walls not perpendicular to the surface that are non-coplanar or arched extending 20 to 500 microns in depth having an increasing inclination from the surface extending inwardly and not parallel to opposing or adjacent walls forming a random or non-random network.

2. The method of claim 1, wherein the one or more bone growth surfaces configured to mimic trabecular bone have discernable nano features on the structural elements or walls exhibiting nano scale features of less than 200 nano meters with the network.

3. The method of claim 2, wherein an area of the one or more bone growth surfaces of the implant with the discernable nano features have a surface area greater than 10 times a same size area at the surface of the structurally solid feature without the discernable nano features.

4. The method of claim 1, wherein an area of the bone growth surface configured to mimic trabecular bone with the discernable nano features has a surface area 100 times or more a same size area of the surface of the structurally solid feature not configured with the discernable nano features.

5. The method of claim 1, wherein the one or more bone growth surfaces is exposed to a laser beam having a power intensity wavelength of around 510-570 nano meters to create the trabecular bone mimicking features with discernable nano features in the one or more bone growth surfaces.

6. The method of claim 5, further includes the step of chemically altering the material to enhance osteoinductivity for new bone growth formation by an increased oxidation at the bone growth surface.

7. The method of claim 6, wherein the step of providing the implant device wherein the implant device is a titanium alloy, and wherein the step of laser etching further includes creating titanium oxide at the surface.

8. The method of claim 1, wherein the implant device is one of a spine implant for bone fusion between vertebrae, or a bone fastener, or an orthopedic device for implantation onto or into bone, or a dental implant device for implantation into the bone structure of a patient.

9. A method of providing enhanced bone growth surfaces on an implant device comprises the steps of: providing an implant device having a structurally solid feature; wherein the one or more bone growth surfaces extend from the structurally solid feature of the implant device and are configured to mimic adult trabecular bone by having trenches, grooves or surface recesses or prominences exhibiting numerous structural elements or walls not perpendicular to the surface that are non-coplanar or arched extending 20 to 500 microns in depth having an increasing inclination from the surface extending inwardly and not parallel to opposing or adjacent walls forming a random or non-random network and wherein the one or more bone growth surfaces configured to mimic adult trabecular bone have discernable nano scale prominences, the nano scale prominences projecting less than 200 nano meters from the one or more bone growth surfaces only visible through magnification of sub-micron resolution exhibiting large surface areas relative to the size of the nano scale prominences configured to enhance and receive new bone growth providing the improved osteoinductive feature and variations of surface features resulting from the manufacturing process and the material composition of the implant device.

10. The method of claim 9, wherein an area of the one or more bone growth surfaces of the implant with the discernable nano scale prominences having a surface area greater with no additional volume than the surface area of the structurally solid feature without the discernable nano scale prominences and nano scale prominences at less than 200 nano meters that are formed by the subtraction laser etching process on the surface of the bone growth surfaces of the implant.

11. The method of claim 9, wherein the one or more bone growth surfaces is exposed to a laser beam having a power intensity wavelength of around 470-570 nano meters to create the trabecular bone mimicking features with discernable nano scale prominences in the one or more bone growth surfaces.

12. The method of claim 9, wherein the implant is made of a metal material or cermet or plastic or bone or any combination thereof.

13. The method of claim 12, wherein the implant when exposed to the laser exhibits an increased oxidation at the surface chemically altering the implant to enhance osteoinductivity for new bone growth formation when implanted.

14. The method of claim 9, wherein the metal is a titanium alloy and the metal when exposed to the laser is enhanced with metal oxide from the device.

15. The method of claim 13, wherein the titanium alloy is 90 percent titanium, 6 percent aluminum and 4 percent vanadium and wherein the oxidation created by the laser alters the chemical structure at the surface by forming titanium oxide, aluminum oxide or vanadium oxide to enhance new bone growth.

16. The method of claim 9, wherein the implant device is one of a spine implant for bone fusion between vertebrae, or a bone fastener, or an orthopedic device for implantation onto or into bone, or a dental implant device for implantation into the bone structure of a patient.

17. The method of claim 9, wherein the device is a dental implant for tooth replacement, the dental implant being an abutment for implantation into the bone structure of the jawbone.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The invention will be described by way of example and with reference to the accompanying drawings in which:

[0027] FIG. 1 is a perspective view of an expandable spinal implant device made according to the present invention.

[0028] FIG. 2 is an enlarged view of a surface made using the process of the present invention.

[0029] FIG. 3 is a magnification of the surface made using the process of the present invention.

[0030] FIG. 4 is an exemplary laser device.

DETAILED DESCRIPTION OF THE INVENTION

[0031] With reference to FIG. 1, a perspective view of an exemplar device of an expandable spinal implant device 10 is shown having been made according to the present invention. As shown, side surfaces 14, 15, 16 have the feature for enhanced osteoinductivity for encouraging new bone to fuse to the device 10 after being installed in the disc space. The device 10 has an enhanced feature that creates a surface area 30 with nano features 32 for new bone growth formation to attach. These surface areas 30 include surfaces in contact with bone on implantation as well as surfaces where new bone growth on the sides of the device helps secure the device in place after bone fusion occurs. Each surface area 30 has nano features 32 shown in FIG. 3. The device 10, as shown, is in a partially expanded condition. The level of expansion can be raised to a higher amount or lowered to a closed position for insertion.

[0032] The enlarged view of FIG. 2 illustrates the appearance of the trabecular bone mimicking surface area 30. The one or more bone growth surfaces 14, 15, 16 extending from a structurally solid feature of the implant device 10, wherein the one or more bone growth surfaces are configured to mimic adult trabecular bone by having trenches, grooves or surface recesses or prominences exhibiting numerous structural elements or walls not perpendicular to the surface that are non-coplanar or arched extending 20 to 500 microns in depth having an increasing inclination from the surface extending inwardly and not parallel to opposing or adjacent walls forming a random or non-random network 18 containing nano features 32.

[0033] FIG. 3 is a highly magnified image that shows the nano features 32 of the surface area 30 in which the entire width of the image shown is only about 2 microns. The scale can be appreciated in the image shown in FIG. 1 of the textured implant device 10 which is 35 mm in length and the trenches, grooves or surface recesses or prominences can be easily seen by eye without magnification. The nano features 32 are only visible through powerful magnification which affords sub-micron resolution. As shown, these nano features 32 exhibit very high surface areas in relation to their size. This large surface area creates advantageous regions to induce and to receive new bone growth. The bone-forming cells attach to these nano features 32 with greater ease and affinity than on solid untreated surfaces of the implant 10. The bone-forming cells become activated to form and remodel new bone through biologic changes in their morphology and chemistry due to their interaction with this unique surface structure. Activation is furthered by cell-cell communication, fostering a tissue based organization that evolves from a cell-based induction.

[0034] In FIG. 4, an exemplary laser etching machine 200 is illustrated that can be used to form bone growth enhancing features. These features can be laid in a network 18 of trenches, grooves or surface recesses or prominences or combinations thereof either in an organized uniform network pattern or a random non-uniform network pattern throughout the exterior surfaces 14, 15, 16. Ideally, these nano channels 30 are created at least along the first and second surfaces 14, 16 of the implant device 10. The nano channels 30 are the result of small laser etched cuts that can be laid out along the entire exterior surfaces in a subtractive laser etching process. These nano channels 30 created by laser etching can be made either by moving the laser 200 about the surface 14, 15, 16 of the implant device to form the nano channels 30; or the implant device 10 can be moved relative to the laser such that the nano channels 30 are laid onto the exterior surfaces 14, 15, 16. Or the process may move both the implant and the laser simultaneously. The nano features 32 individually create an improved osteoinductive effect at the surface of the implant device 10. While the network 18 can be uniform, the nano features 32 themselves are random having non-coplanar walls or arches with increasing inclination from the depth to the surface. This means that the formation of new bone once implanted into the patient can be accelerated and the network 18 of nano features 32 provide features that help assist in providing attachment locations for the new bone formation. This continuous and progressive architecture with Z-vector variation in addition to the macro-surface geometry is an important feature that is provided in the current invention and is ideal in that it does not require smooth or flat exterior surfaces to form the channels which are effectively etched into the exterior surface. The channels can be created as long as the path of the laser beam is unobstructed.

[0035] It is noted any implant device can be treated post manufacturing to create these surfaces on an existing implant device. Furthermore, the process can be used to form the surfaces on any number of implants where osteoinductive bone grown enhancement is desired. These can be bone fasteners, pedicle screws, cervical plates, spinal fusion cages, dental implants, non-spinal orthopedic implants and any bone growth implant device or bone-interfacing device that benefits from bone growth into and/or around the surface of the implant.

[0036] The materials the implant device 10 is made of can be any suitable implant material of metal, plastic or bone and the benefits of enhanced osteoinductivity can be achieved.

[0037] These and other aspects of the present invention are believed to greatly enhance the ability of the present device made by laser etching to provide an improved implant fusion device.

[0038] Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described which will be within the full intended scope of the invention as defined by the following appended claims.