The present invention relates to a method and device for increasing diffusibility of metallic surfaces and its applications. Particularly, the present invention relates to a surface treatment method combining a mechanic means and a chemical means, whereby the mechanic means increases the diffusibility of the surface while the chemical means forms a chemically modified surface layer for improved properties suitable for particular application of the metallic materials, especially in the bio-medical areas.
Stainless steel is widely used in daily life and in industries. For example, it is widely used in the bio-medial industry to manufacture orthopedic, dental and other implants, such as bone plates, artificial hip joints, intramedullary nails, etc, see U.S. Pat. Nos. 4,964,925, 4,718,908, and 4,775,426. However, it is known that stainless steel has its shortcomings. Since the surface hardness of stainless steel is low (<300 Hv), wear resistance of the implants is weak in vivo. The weak wear resistance may damage the implant fixation and the wear debris is harmful to the host tissue. In addition, stainless steel has low pit corrosion resistance, especially in the warm salty body fluid containing Cl− ions. To overcome some of the weaknesses of stainless steel, U.S. Pat. Nos. 5,205,921 and 5,482,731 describe two processes to coat bioactive calcium phosphate coatings on metallic implant devices for their bioactive fixation. U.S. Pat. No. 5,057,108 discloses a surface treatment process for stainless steel orthopedic implant devices, in which a heavily cold-worked outer layer is formed that enhances fatigue properties of the devices after two shot blasting steps, electropolishing and passivation.
In another bio-medical areas, with the fast development of interventional therapeutic procedures, NiTi shape memory alloy wires are being widely used to produce cardiovascular, tracheal, oesophageal and other implants due to their excellent mechanical performance, strong shape memory effect, super-elastic properties, reasonably good chemical resistance and biocompatibility, see U.S. Pat. Nos. 6,375,458, 6,224,625, 5,882,444, C.N. Pat. Nos. 02124291.7, 02240165.2, etc. The wide application of these implants implies two concerns in terms of biocompatibility. First, there is the possibility of adverse tissue reactions after implantation, suggesting that the biocompatibility of NiTi wires is not perfect and needs further improvement. Second, the out-diffusion of harmful Ni+ ions from NiTi implants, which have been found to be carcinogenic during prolonged use inside the human body, poses a potential health problem. U.S. Pat. No. 7,000,305 describes a process to coat NiTi or other wires with the expanded fluoropolymer after heat setting to reduce platelet adhesion to the stent. No other inorganic coatings, e.g. titania or carbon coatings that have good hemocompatibility, on NiTi wires are found in the prior art disclosures. By adding a separate layer of coating material which is different from the underlying material, stainless steel or NiTi, for example, is not an ideal method to modify metallic surfaces and there is a need for a thinking in a different direction for different solutions.
Accordingly, one object of the present invention is to provide a new surface modification method which does not relying on a separate coating layer on the metallic surfaces to increase hardness and corrosion resistance of stainless steel and to reduce Ni release from NiTi wires. Another object of the present invention is to provide an automatic device for mechanically retreating metallic surfaces
This and other objects of the present invention are realized by providing a method that combines mechanic and chemical means to enhance physical and chemical properties of the metallic surfaces to suit particular purposes, for example, for application as implants. In essence, the present invention uses a mechanic process to increase diffusibility of the metallic surfaces to be treated then follows up with chemical process to physically and chemically changes the surfaces. The mechanical process is to facilitates the subsequent chemical process to achieve effects either the mechanical process or the chemically process alone could not achieve. It is believed that the mechanical process create certain nanocrystalline surface structure, characterized by ultrafine grains, typically with at least one dimension of less than 100 nm. Although not be bound by the theory, the nanocryatlline surfaces structure may serve as the basis of the observed enhancement of surface diffusibility. Several mechanical methods and mechanical devices have been invented to generate a layer of nanometric microstructures, or nanostructures on metallic pieces, as disclosed the present inventor's previous U.S. Pat. Nos. (7,147,726 and 7,300,622). The surface modification produced according to the present invention have the following advantages: (1) the layer with nanostructures are directly formed on the surface of metallic pieces and it has the same material as the substrate, and thus the nanostructured layer is dense and highly pure; (2) the grain size has a smooth transition from the nanostructured surface layer to the underlying substrate, and the absence of a clear interface can avoid bonding problem that is often encountered for coating materials; and (3) the process is carried out by mechanical means in air or in low level vacuum conditions, and therefore the complex electrical devices e.g. for sputtering or vaporizing and the high level vacuum pumps are avoided. The low requirement for operational atmosphere is beneficial for treating large pieces in industrial applications.
As a particular example, due to the increase in hardness of the treated stainless steel, 316 stainless steel which is commonly used in implants can now be replaced 304 stainless steel with a lower nickel content.
Furthermore, a new surface treatment device is designed so as to accommodate metallic medical implants with complex shapes and large sizes.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages, and specific objects attained by its use, reference should be made to the drawings and the following description in which there are illustrated and described preferred embodiments of the invention.
According to a variant of embodiment represented in
According to another variant of embodiment represented in
The device is not limited to the embodiments described above, but encompasses any embodiment that makes it possible to generate nanostructured layers on metallic implants by the mechanical means.
The general principle for choosing the parameters to generate nanostructures on the implants according to the invention is that the greater the kinetic energy of the balls, the greater the level of stress generated in the underlying layer. The upper limit of the kinetic energy is defined particularly by the heating caused by the release of this kinetic energy during the impact on the surface being treated, and by the mechanical strength of the balls and of the material constituting the implants. The hardness of the balls plays a role, particularly in the transfer of kinetic energy from the ball to the surface of the implants. Experience has shown that the larger the diameter of the balls used, within a range of dimensions on the order of a few hundred microns to a few millimeters, the larger the nanostructured layer obtained.
Likewise, the treatment time is involved in determining the thickness of the nanostructures. It has been noted that up to a given time value, which is different and depends on the size of the balls, the more the time increases, the more the thickness of the nanostructured layer increases up to a time that corresponds to saturation and allows no further modification of the thickness of the layer. This given value is obtained either through experience, or from a mathematical model for a given material. However, when the time becomes greater than the given value, the thickness of the nanostructured layer decreases. This phenomenon is due to the fact that the impact of the balls on the treated surface generates an emission of heat, which heats up the material. Beginning at a certain threshold, the result of the heat is to increase the size of the metal grains.
The rotation speed of the implant being treated, e.g. from 0.5 rpm to 5 rpm, is another parameter. The rotation will help decrease local temperature rising of the treated implant, because the side opposite to the sonotrode has less bombardment and there is an interval for it to release heat. The higher the rotation speed is, the less heat is accumulated in a local area of the treated surface in a unit time. Thus, for thin wires or thin sheets, the rotation speed should be larger so as to avoid local overheating by bombardment. For the implants with large dimension, the rotation speed can be lower, but grain growth caused by the rapid local temperature rising should be also avoided.
Other parameters may also act on the nanostructure formation during treatment. In the device where an ultrasonic generator is used to set the balls in motion, the acoustic pressure generated by the sound waves may influence the nanostructure generating process. The temperature rising of the implant can be reduced with a cooling system so as to avoid the overheating effect on grain growth of the implant. The device can also be placed in an inert gas atmosphere or in vacuum to avoid oxidization of the surface of the metallic implants being treated.
The generation of nanostructures on the treated surfaces of the implants causes a modification of the law of diffusion in the treated area. In essence, the multiplication of the metal grains also multiplies the number of boundaries between the grains. These boundaries constitute nanometric channels that allow the diffusion of chemical compounds. Thus, these compounds can penetrate more deeply and more completely into the treated surface of the implants, making it possible to obtain a compound layer with advantageous mechanical and chemical properties.
As an example,
In fact, the presence of nanostructures, and in particular nanometric diffusion channels, allows faster diffusion of compounds into the superficial layer of metal pieces. The above results have evidenced that the growth of nitride layer on stainless steel plates pre-treated by generating nanostructures is quicker than that on the plate without pre-treatment, that is, the nitriding kinetics is accelerated. In addition, optical microscopic observation shows that the nitride layer is more even and dense for the pre-treated plates than the plates without pre-treatment.
The device for generating nanostructures in a given thickness on metallic implants comprises a working chamber that can be divided into multiple rooms, means for setting in motion a given quantity of perfectly spherical balls of given dimension at a given speed in each room for a given duration, means for reusing the balls continuously in each room, and means for mounting and rotating the implants at a given speed to obtain variable angles of incidence at the same impact point, so that the impact points as a group cover the entire surface of the implant. The method for surface modifying metallic implants comprises means for forming protective compound layers in a sealed chamber or in a chemical solution at given conditions by using the high diffusion properties of the nanostructured layers.
In another embodiment, the working chamber has two rooms with a fence to separate them, and at least one room has adjustable roof height.
In another embodiment, the means for setting the balls in motion includes an ultrasonic generator at the bottom of each room, causing the balls to move in random directions, and the means for reusing the balls is the sloping floor of each room.
In another embodiment, the implant to be treated is a stainless steel intramedullary nail with diameter 10 mm and length up to 240 mm.
In another embodiment, the implant to be treated is a stainless steel bone plate with width 40 mm and length 220 mm.
In another embodiment, the implant to be treated is a stainless steel bone plate with width 50 mm and length 120 mm.
In another embodiment, the implant to be treated is a stainless steel artificial hip joint with stem length 90 mm and head diameter 28 mm.
In another embodiment, the implant to be treated is NiTi wire with diameter from 0.1 mm to 0.5 mm.
In another embodiment, the implant is fixed by clamps or other fixtures, which are mounted in the tubes driven by a motor through gears at a rotation speed between 0.5 rpm and 5 rpm.
In another embodiment, the linear moving speed of the NiTi wire is between 10 cm/min and 40 cm/min.
In another embodiment, the perfectly spherical balls are made of stainless steel.
In another embodiment, the perfectly spherical balls are made of zirconia.
In another embodiment, the diameter of the balls is between 0.3 mm and 3 mm, depending on the thickness of the nanostructures desired by the user.
In another embodiment, the balls are of a quantity such that, when the means for setting them in motion using ultrasound are inactive, they occupy a surface area greater than 30% of the surface of the sonotrode.
In another embodiment, the ball speed is between 5 mps and 100 mps.
In another embodiment, for a given ball size and a given material constituting the implant with given size, the projection time is determined based on the nanostructured layer thickness desired by the user.
In another embodiment, the projection time of the balls is between 30 s and 1800 s.
In another embodiment, the device for generating nanostructures includes means for adjusting emission time of the balls and their speed.
In another embodiment, the device includes means for adjusting the distance between the emission source of the balls and the implant to be treated.
In another embodiment, the distance is between 20 mm and 80 mm.
In another embodiment, the device for generating nanostructures includes means for performing a local cooling of the treated area of the implant.
In another embodiment, the projection step is performed after the chamber has been filled with inert gas.
In another embodiment, the device is enclosed in a vacuum cabinet.
In another embodiment, the device is enclosed in an acoustic isolation chamber.
In another embodiment, the step to form a protective nitride layer on stainless steel implants is plasma nitriding comprising the placement of implants in a nitrogen atmosphere at a given temperature around 450° C. for a given amount of time between 30 min to 120 min.
In another embodiment, the step to form a protective oxide layer on NiTi wires includes the placement of the wires in H2O2 solution with concentration from 10% to 30% at 60-100° C. for a given time between 12 and 24 hr.
While there have been described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes, in the form and details of the embodiments illustrated, may be made by those skilled in the art without departing from the spirit of the invention. The invention is not limited by the embodiments described above which are presented as examples only but can be modified in various ways within the scope of protection defined by the appended patent claims.