US 12,251,312 B1
Medical devices and methods for forming medical devices having a porous structure
Roger Ryan Dees, Jr., Drummonds, TN (US)
Assigned to SMITH & NEPHEW, INC., Memphis, TN (US); SMITH & NEPHEW ORTHOPAEDICS AG SMITH, Zug (CH); and NEPHEW ASIA PACIFIC PTE. LIMITED, Singapore (SG)
Filed by Smith & Nephew, Inc., Memphis, TN (US); Smith & Nephew Orthopaedics AG, Zug (CH); and Smith & Nephew Asia Pacific Pte. Limited, Singapore (SG)
Filed on Apr. 13, 2023, as Appl. No. 18/134,229.
Application 18/134,229 is a continuation in part of application No. 17/063,504, filed on Oct. 5, 2020, granted, now 11,638,776.
Claims priority of provisional application 62/911,690, filed on Oct. 7, 2019.
This patent is subject to a terminal disclaimer.
Int. Cl. A61L 24/02 (2006.01); A61F 2/30 (2006.01); A61L 27/30 (2006.01); A61L 27/56 (2006.01)
CPC A61F 2/30767 (2013.01) [A61L 27/30 (2013.01); A61F 2310/00023 (2013.01); A61F 2310/00029 (2013.01); A61F 2310/00089 (2013.01); A61L 2420/02 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method of coating an orthopedic medical implant, the method comprising:
forming a plurality of texture features in an outer surface of the implant, wherein adjacent texture features are separated by an indentation, and wherein the outer surface of the implant is cobalt chrome or titanium; and
forming a porous coating atop the outer surface, including within the indentations between the plurality of texture features and over the plurality of texture features, wherein the porous coating includes a plurality of coating structures, and wherein the plurality of texture features have a height and the porous coating has a thickness, and wherein the thickness of the porous coating is less than or equal to the height of the plurality of texture features;
wherein one or more of the coating structures of a first coating structure group of the plurality of coating structures is in direct contact with the plurality of texture features, the outer surface, or a combination thereof;
wherein forming the porous coating comprises:
initially applying the first coating structure group of the plurality of coating structures atop the outer surface within the indentations between the plurality of texture features and over the plurality of texture features; and
subsequently applying a second coating structure group of the plurality of coating structures; and
wherein the first coating structure group has a first porosity and the second coating structure group has a second porosity, the first porosity is less than the second porosity.