US5725573A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Medical implants made of metal alloys bearing cohesive diamond like carbon coatings
Assignee: Southwest Research Institute
•
Filing: 1996-04-10
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Granted: 1998-03-10
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Expires: 2016-04-10
Abstract
Abstract The present invention provides a method for coating a metal alloy component of a medical implant, particularly a component of a heart valve made of a titanium base alloy, with a strongly adhered coating of diamond-like carbon. The method uses ion beam assisted deposition to form a gradient at the surface of the titanium alloy comprising metal alloy/metal-silicide/(silicon or germanium)/silicon- or germanium-carbide/DLC.
Inventors
- 👤 Geoffrey Dearnaley
- 👤 James Lankford, Jr.
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 03:23
CPC Classifications
C; C23; C23C; C23C16/00; C23C16/02; C23C16/0209; A; A61; A61F; A61F2/00; A61F2/02; A61F2/24; A61F2/30; A61F2/46; A61F2/468; A61L; A61L33/00; A61L33/02; A61L33/025; C23C16/0272; C23C16/22; C23C16/26; C23C16/44; C23C16/48; A61F2310/00; A61F2310/00005; A61F2310/00011; A61F2310/00023; A61F2310/00389; A61F2310/00574; A61F2310/0058
Claims Analysis
Total Claims: 42
Claim 1
Independent Claim
282 words
A method for coating a metal alloy component of a medical implant with diamond-like carbon comprising: exposing said component to a vacuum at a pressure of about 10 -5 torr or less; heating said component to a first temperature of about 300° C. (149° F.) or, if said metal alloy is temperature sensitive, to a highest temperature acceptable for said metal alloy; depositing onto said component an intermediate material selected from the group consisting of silicon, germanium, and a combination thereof, in an amount sufficient to form an intermetallic material selected from the group consisting of a metal-silicide, a metal-germanide, and a combination thereof at said outer surface of said substrate cohesively bonded to an interlayer of said intermediate material; substantially simultaneous with said depositing of said intermediate material, bombarding said intermediate material with a first energetic beam of ions at a first energy, a first ion arrival ratio, and for a first amount of time sufficient to form said intermetallic bonding layer cohesively bonded to said interlayer; condensing a diamond-like carbon precursor onto said interlayer at a second temperature and for a second amount of time sufficient to form a film of precursor molecules on said interlayer, wherein said second temperature is sufficiently low that said diamond-like carbon precursor is not vaporized off of said substrate; substantially simultaneous with said condensing of said diamond-like carbon precursor, bombarding said diamond-like carbon precursor with a second energetic beam of ions at a second energy, a second ion arrival ratio, and for a third amount of time sufficient to form a carbide bonding layer selected from the group consisting of silicon-carbide, germanium-carbide, and a combination thereof, cohesively bonded to a coating of diamond-like carbon.
Claim 2
Independent Claim
282 words
A method for coating a metal alloy component of a medical implant with diamond-like carbon comprising: exposing said component to a vacuum at a pressure of about 10 -5 torr or less; heating said component to a first temperature of about 300° C. (149° F.) or, if said metal alloy is temperature sensitive, to a highest temperature acceptable for said metal alloy; depositing onto said component an intermediate material selected from the group consisting of silicon, germanium, and a combination thereof, in an amount sufficient to form an intermetallic material selected from the group consisting of a metal-silicide, a metal-germanide, and a combination thereof at said outer surface of said substrate cohesively bonded to an interlayer of said intermediate material; substantially simultaneous with said depositing of said intermediate material, bombarding said intermediate material with a first energetic beam of ions at a first energy, a first ion arrival ratio, and for a first amount of time sufficient to form said intermetallic bonding layer cohesively bonded to said interlayer; condensing a diamond-like carbon precursor onto said interlayer at a second temperature and for a second amount of time sufficient to form a film of precursor molecules on said interlayer, wherein said second temperature is sufficiently low that said diamond-like carbon precursor is not vaporized off of said substrate; substantially simultaneous with said condensing of said diamond-like carbon precursor, bombarding said diamond-like carbon precursor with a second energetic beam of ions at a second energy, a second ion arrival ratio, and for a third amount of time sufficient to form a carbide bonding layer selected from the group consisting of silicon-carbide, germanium-carbide, and a combination thereof, cohesively bonded to a coating of diamond-like carbon.
Claim 3
Dependent Claim
30 words
The method of claim 1 wherein said metal alloy comprises a metal selected from the group consisting of cobalt, nickel, titanium, zirconium, chromium, molybdenum, tungsten, platinum, palladium, and combinations thereof.
Claim 4
Dependent Claim
29 words
The method of claim 1 wherein said component comprises a metal alloy selected from the group consisting of stainless steel, a cobalt base alloy, and a titanium base alloy.
Claim 5
Dependent Claim
14 words
The method of claim 3 wherein said second beam of ions comprises nitrogen ions.
Claim 6
Dependent Claim
18 words
The method of claim 4 wherein said first energy and said second energy are between about 10-30 keV.
Claim 7
Dependent Claim
15 words
The method of claim 3 wherein said second temperature is about 80° C. (26° F.).
Claim 8
Dependent Claim
15 words
The method of claim 5 wherein said second temperature is about 80° C. (26° F.).
Claim 9
Dependent Claim
22 words
The method of claim 7 wherein said intermediate material is deposited onto said substrate to a thickness of between about 100-200 nm.
Claim 10
Independent Claim
262 words
A method for coating a titanium base component of a medical implant with diamond-like carbon comprising: exposing said component to a vacuum at a pressure of about 10 -5 torr or less; heating said component to at least about 600° C.-650° C. (1112°-1202° F.); depositing onto said component an intermediate material selected from the group consisting of silicon, germanium, and a combination thereof, in an amount sufficient to form an intermetallic material selected from the group consisting of titanium-silicide, titanium-germanide, and a combination thereof at said outer surface of said substrate cohesively bonded to an interlayer of said intermediate material; substantially simultaneous with said depositing of said intermediate material, bombarding said intermediate material with a first energetic beam of ions at a first energy, a first ion arrival ratio, and for a first amount of time sufficient to form said intermetallic bonding layer cohesively bonded to said interlayer; condensing a diamond-like carbon precursor onto said interlayer at a second temperature and for a second amount of time sufficient to form a film of precursor molecules on said interlayer, wherein said second temperature is sufficiently low that said diamond-like carbon precursor is not vaporized off of said substrate; substantially simultaneous with said condensing of said diamond-like carbon precursor, bombarding said diamond-like carbon precursor with a second energetic beam of ions at a second energy, a second ion arrival ratio, and for a third amount of time sufficient to form a carbide bonding layer selected from the group consisting of silicon-carbide, germanium-carbide, and a combination thereof, cohesively bonded to a coating of diamond-like carbon.
Claim 11
Independent Claim
262 words
A method for coating a titanium base component of a medical implant with diamond-like carbon comprising: exposing said component to a vacuum at a pressure of about 10 -5 torr or less; heating said component to at least about 600° C.-650° C. (1112°-1202° F.); depositing onto said component an intermediate material selected from the group consisting of silicon, germanium, and a combination thereof, in an amount sufficient to form an intermetallic material selected from the group consisting of titanium-silicide, titanium-germanide, and a combination thereof at said outer surface of said substrate cohesively bonded to an interlayer of said intermediate material; substantially simultaneous with said depositing of said intermediate material, bombarding said intermediate material with a first energetic beam of ions at a first energy, a first ion arrival ratio, and for a first amount of time sufficient to form said intermetallic bonding layer cohesively bonded to said interlayer; condensing a diamond-like carbon precursor onto said interlayer at a second temperature and for a second amount of time sufficient to form a film of precursor molecules on said interlayer, wherein said second temperature is sufficiently low that said diamond-like carbon precursor is not vaporized off of said substrate; substantially simultaneous with said condensing of said diamond-like carbon precursor, bombarding said diamond-like carbon precursor with a second energetic beam of ions at a second energy, a second ion arrival ratio, and for a third amount of time sufficient to form a carbide bonding layer selected from the group consisting of silicon-carbide, germanium-carbide, and a combination thereof, cohesively bonded to a coating of diamond-like carbon.
Claim 12
Dependent Claim
14 words
The method of claim 9 wherein said second beam of ions comprises nitrogen ions.
Claim 13
Dependent Claim
18 words
The method of claim 9 wherein said first energy and said second energy are between about 10-30 keV.
Claim 14
Dependent Claim
18 words
The method of claim 10 wherein said first energy and said second energy are between about 10-30 keV.
Claim 15
Dependent Claim
15 words
The method of claim 9 wherein said second temperature is about 80° C. (26° F.).
Claim 16
Dependent Claim
15 words
The method of claim 10 wherein said second temperature is about 80° C. (26° F.).
Claim 17
Dependent Claim
15 words
The method of claim 12 wherein said second temperature is about 80° C. (26° F.).
Claim 18
Dependent Claim
22 words
The method of claim 9 wherein said intermediate material is deposited onto said substrate to a thickness of between about 100-200 nm.
Claim 19
Dependent Claim
22 words
The method of claim 10 wherein said intermediate material is deposited onto said substrate to a thickness of between about 100-200 nm.
Claim 20
Dependent Claim
22 words
The method of claim 12 wherein said intermediate material is deposited onto said substrate to a thickness of between about 100-200 nm.
Claim 21
Dependent Claim
22 words
The method of claim 15 wherein said intermediate material is deposited onto said substrate to a thickness of between about 100-200 nm.
Claim 22
Dependent Claim
264 words
A titanium base component of a medical implant comprising a coating of diamond-like carbon produced by a process comprising: exposing said component to a vacuum at a pressure of about 10 -5 torr or less; heating said component to at least about 600° C.-650° C. (1112°-1202° F.); depositing onto said component an intermediate material selected from the group consisting of silicon, germanium, and a combination thereof, in an amount sufficient to form an intermetallic material selected from the group consisting of titanium-silicide, titanium-germanide, and a combination thereof at said outer surface of said substrate cohesively bonded to an interlayer of said intermediate material; substantially simultaneous with said depositing of said intermediate material, bombarding said intermediate material with a first energetic beam of ions at a first energy, a first ion arrival ratio, and for a first amount of time sufficient to form said intermetallic bonding layer cohesively bonded to said interlayer; condensing a diamond-like carbon precursor onto said interlayer at a second temperature and for a second amount of time sufficient to form a film of precursor molecules on said interlayer, wherein said second temperature is sufficiently low that said diamond-like carbon precursor is not vaporized off of said substrate; substantially simultaneous with said depositing of said intermediate material, bombarding said diamond-like carbon precursor with a second energetic beam of ions at a second energy, a second ion arrival ratio, and for a third amount of time sufficient to form a carbide bonding layer selected from the group consisting of silicon-carbide, germanium-carbide, and a combination thereof, cohesively bonded to a coating of diamond-like carbon.
Claim 23
Dependent Claim
264 words
A titanium base component of a medical implant comprising a coating of diamond-like carbon produced by a process comprising: exposing said component to a vacuum at a pressure of about 10 -5 torr or less; heating said component to at least about 600° C.-650° C. (1112°-1202° F.); depositing onto said component an intermediate material selected from the group consisting of silicon, germanium, and a combination thereof, in an amount sufficient to form an intermetallic material selected from the group consisting of titanium-silicide, titanium-germanide, and a combination thereof at said outer surface of said substrate cohesively bonded to an interlayer of said intermediate material; substantially simultaneous with said depositing of said intermediate material, bombarding said intermediate material with a first energetic beam of ions at a first energy, a first ion arrival ratio, and for a first amount of time sufficient to form said intermetallic bonding layer cohesively bonded to said interlayer; condensing a diamond-like carbon precursor onto said interlayer at a second temperature and for a second amount of time sufficient to form a film of precursor molecules on said interlayer, wherein said second temperature is sufficiently low that said diamond-like carbon precursor is not vaporized off of said substrate; substantially simultaneous with said depositing of said intermediate material, bombarding said diamond-like carbon precursor with a second energetic beam of ions at a second energy, a second ion arrival ratio, and for a third amount of time sufficient to form a carbide bonding layer selected from the group consisting of silicon-carbide, germanium-carbide, and a combination thereof, cohesively bonded to a coating of diamond-like carbon.
Claim 24
Dependent Claim
106 words
A titanium base component of a medical implant having an outer surface comprising a sequential gradient as follows: an intermediate material selected from the group consisting of silicon, germanium, and a combination thereof, chemically bonded to said titanium in said substrate forming an intermetallic material selected from the group consisting of titanium silicide, titanium germanide, and a combination thereof; an interlayer material comprising said intermediate material cohesively bonded to said intermetallic material; carbon chemically bonded to said interlayer material, forming a carbide selected from the group consisting of silicon carbide, germanium carbide, and a combination thereof; and a diamond-like carbon coating cohesively bonded to said carbide.
Claim 25
Dependent Claim
106 words
A titanium base component of a medical implant having an outer surface comprising a sequential gradient as follows: an intermediate material selected from the group consisting of silicon, germanium, and a combination thereof, chemically bonded to said titanium in said substrate forming an intermetallic material selected from the group consisting of titanium silicide, titanium germanide, and a combination thereof; an interlayer material comprising said intermediate material cohesively bonded to said intermetallic material; carbon chemically bonded to said interlayer material, forming a carbide selected from the group consisting of silicon carbide, germanium carbide, and a combination thereof; and a diamond-like carbon coating cohesively bonded to said carbide.
Claim 26
Dependent Claim
13 words
The component of claim 21 wherein said medical implant is a heart valve.
Claim 27
Dependent Claim
16 words
The component of claim 21 further comprising nitrogen bonded to carbon atoms in said diamond-like carbon.
Claim 28
Dependent Claim
16 words
The component of claim 22 further comprising nitrogen bonded to carbon atoms in said diamond-like carbon.
Claim 29
Dependent Claim
103 words
A solid metal alloy component having an outer surface comprising a sequential gradient as follows: a intermediate material selected from the group consisting of silicon, germanium, and a combination thereof, chemically bonded to said metal alloy in said substrate forming an intermetallic material selected from the group consisting of a metal-silicide, a metal-germanide, and a combination thereof; an interlayer comprising said intermediate material cohesively bonded to said intermetallic material; carbon chemically bonded to said interlayer material, forming a carbide selected from the group consisting of silicon carbide, germanium carbide, and a combination thereof; and a diamond-like carbon coating cohesively bonded to said carbide.
Claim 30
Dependent Claim
103 words
A solid metal alloy component having an outer surface comprising a sequential gradient as follows: a intermediate material selected from the group consisting of silicon, germanium, and a combination thereof, chemically bonded to said metal alloy in said substrate forming an intermetallic material selected from the group consisting of a metal-silicide, a metal-germanide, and a combination thereof; an interlayer comprising said intermediate material cohesively bonded to said intermetallic material; carbon chemically bonded to said interlayer material, forming a carbide selected from the group consisting of silicon carbide, germanium carbide, and a combination thereof; and a diamond-like carbon coating cohesively bonded to said carbide.
Claim 31
Dependent Claim
21 words
The metal alloy component of claim 25 wherein said diamond-like carbon coating has a thickness of at least about 1 μ.
Claim 32
Dependent Claim
19 words
The metal alloy component of claim 25 further comprising nitrogen bonded to carbon atoms in said diamond-like carbon coating.
Claim 33
Dependent Claim
19 words
The metal alloy component of claim 26 further comprising nitrogen bonded to carbon atoms in said diamond-like carbon coating.
Claim 34
Dependent Claim
279 words
A solid metal alloy component coated with diamond-like carbon by a process comprising: exposing said component to a vacuum at a pressure of about 10 -5 torr or less; heating said component to a first temperature of about 300° C. (149° F.) or, if said metal alloy is temperature sensitive, to a highest temperature acceptable for said metal alloy; depositing onto said component an intermediate material selected from the group consisting of silicon, germanium, and a combination thereof in an amount sufficient to form an intermetallic material selected from the group consisting of a metal-silicide, a metal-germanide, and a combination thereof at an outer surface of said component cohesively bonded to an interlayer of said intermediate material; substantially simultaneous with said depositing of said intermediate material, bombarding said intermediate material with a first energetic beam of ions at a first energy, a first ion arrival ratio, and for a first amount of time sufficient to form said intermetallic bonding layer cohesively bonded to said interlayer; condensing a diamond-like carbon precursor onto said interlayer at a second temperature and for a second amount of time sufficient to form a film of precursor molecules on said interlayer, wherein said second temperature is sufficiently low that said diamond-like carbon precursor is not vaporized off of said substrate; substantially simultaneous with said condensing of said diamond-like carbon precursor, bombarding said diamond-like carbon precursor with a second energetic beam of ions at a second energy, a second ion arrival ratio, and for a third amount of time sufficient to form a carbide bonding layer selected from the group consisting of silicon-carbide, germanium-carbide, and a combination thereof cohesively bonded to a coating of diamond-like carbon.
Claim 35
Dependent Claim
279 words
A solid metal alloy component coated with diamond-like carbon by a process comprising: exposing said component to a vacuum at a pressure of about 10 -5 torr or less; heating said component to a first temperature of about 300° C. (149° F.) or, if said metal alloy is temperature sensitive, to a highest temperature acceptable for said metal alloy; depositing onto said component an intermediate material selected from the group consisting of silicon, germanium, and a combination thereof in an amount sufficient to form an intermetallic material selected from the group consisting of a metal-silicide, a metal-germanide, and a combination thereof at an outer surface of said component cohesively bonded to an interlayer of said intermediate material; substantially simultaneous with said depositing of said intermediate material, bombarding said intermediate material with a first energetic beam of ions at a first energy, a first ion arrival ratio, and for a first amount of time sufficient to form said intermetallic bonding layer cohesively bonded to said interlayer; condensing a diamond-like carbon precursor onto said interlayer at a second temperature and for a second amount of time sufficient to form a film of precursor molecules on said interlayer, wherein said second temperature is sufficiently low that said diamond-like carbon precursor is not vaporized off of said substrate; substantially simultaneous with said condensing of said diamond-like carbon precursor, bombarding said diamond-like carbon precursor with a second energetic beam of ions at a second energy, a second ion arrival ratio, and for a third amount of time sufficient to form a carbide bonding layer selected from the group consisting of silicon-carbide, germanium-carbide, and a combination thereof cohesively bonded to a coating of diamond-like carbon.
Claim 36
Dependent Claim
30 words
The component of claim 29 wherein said component comprises a metal alloy selected from the group consisting of cobalt, nickel, titanium, zirconium, chromium, molybdenum, tungsten, platinum, palladium, and combinations thereof.
Claim 37
Dependent Claim
19 words
The component of claim 29 wherein said diamond-like carbon coating has a thickness of at least about 1 μ.
Claim 38
Dependent Claim
19 words
The component of claim 30 wherein said diamond-like carbon coating has a thickness of at least about 1 μ.
Claim 39
Dependent Claim
14 words
The component of claim 29 wherein said second beam of ions comprises nitrogen ions.
Claim 40
Dependent Claim
14 words
The component of claim 30 wherein said second beam of ions comprises nitrogen ions.
Claim 41
Dependent Claim
14 words
The component of claim 31 wherein said second beam of ions comprises nitrogen ions.
Claim 42
Dependent Claim
14 words
The component of claim 32 wherein said second beam of ions comprises nitrogen ions.
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| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 2001-03-09 | 2001-09-08 | 2002-03-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2005-03-09 | 2005-09-08 | 2006-03-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2009-03-09 | 2009-09-08 | 2010-03-10 | $7700.00 | Window Closed / Lapsed |