Implants having three distinct surfaces

Abstract

An interbody spinal implant having at least three distinct surfaces including (1) at least one integration surface having a roughened surface topography including macro features, micro features, and nano features, without sharp teeth that risk damage to bone structures; (2) at least one graft contact surface having a coarse surface topography including micro features and nano features; and (3) at least one soft tissue surface having a substantially smooth surface including nano features. Also disclosed are processes of fabricating the different surface topographies, which may include separate macro processing, micro processing, and nano processing steps.

What is claimed is: 
     
         1 . An implant, comprising a body that is generally oval-shaped in transverse cross section and comprises a top surface, a bottom surface, opposing lateral sides, opposing anterior and posterior portions, a substantially hollow center, a sharp edge at the junction of the anterior portion and the top surface, a sharp edge at the junction of the anterior portion and the bottom surface, and a single vertical aperture extending from the top surface to the bottom surface, having maximum width at its center, and defining a transverse rim on the top surface and on the bottom surface, said transverse rim having variable width or thickness and at least a portion with an integration surface comprising macro features, micro features, and nano features, wherein the opposing lateral sides and the opposing anterior and posterior portions include a substantially smooth surface comprising nano features. 
     
     
         2 . The implant of  claim 1 , wherein the body comprises a metal. 
     
     
         3 . The implant of  claim 2 , wherein the metal comprises titanium or an alloy thereof. 
     
     
         4 . The implant of  claim 1 , wherein the posterior portion comprises a generally tapered nose. 
     
     
         5 . The implant of  claim 1 , wherein the junction of the posterior portion and the top surface, and the junction of the posterior portion and the bottom surface comprises a blunt and radiused surface without the integration surface. 
     
     
         6 . The implant of  claim 1 , wherein the body comprises at least one transverse aperture extending through each of the opposing lateral sides and which is in communication with the substantially hollow center. 
     
     
         7 . The implant of  claim 1 , wherein the body comprises a lordotic angle. 
     
     
         8 . The implant of  claim 1 , wherein the anterior portion comprises at least one opening extending through the anterior portion and which is in communication with the substantially hollow center. 
     
     
         9 . The implant of  claim 1 , wherein the single vertical aperture is surrounded by internal surfaces of the body comprising a first graft contact surface comprising micro features and nano features. 
     
     
         10 . The interbody spinal implant of  claim 1 , wherein the integration surface comprises a roughness average amplitude, Ra, of about 8 to 200 microns, and the substantially smooth surface comprises a roughness average amplitude, Ra, of about 0.01 to 2 microns. 
     
     
         11 . The implant of  claim 1 , wherein the macro features have a mean spacing between about 400 to 2000 microns, a maximum peak-to-valley height between about 40 to 500 microns, and an average amplitude between about 20 to 200 microns; the micro features have a mean spacing between about 20 to 400 microns, a maximum peak-to-valley height between about 2 to 40 microns, and an average amplitude between about 1 to 20 microns; and each of the nano features have a mean spacing between about 0.5 to 20 microns, a maximum peak-to-valley height between about 0.2 to 2 microns, and an average amplitude between about 0.1 to 1 microns. 
     
     
         12 . The implant of  claim 1 , wherein the macro features have a mean spacing between about 750 to 1750 microns, a maximum peak-to-valley height between about 150 to 400 microns, and an average amplitude between about 50 to 150 microns; the micro features have a mean spacing between about 100 to 300 microns, a maximum peak-to-valley height between about 2 to 20 microns, and an average amplitude between about 4 to 10 microns; and each of the nano features have a mean spacing between about 1 to 15 microns, a maximum peak-to-valley height between about 0.2 to 1.8 microns, and an average amplitude between about 0.01 to 1 microns. 
     
     
         13 . The implant of  claim 1 , wherein the macro features have a mean spacing between about 1000 to 1500 microns, a maximum peak-to-valley height between about 250 to 300 microns, and an average amplitude between about 100 to 125 microns; the micro features have a mean spacing between about 200 to 250 microns, a maximum peak-to-valley height between about 9 to 13 microns, and an average amplitude between about 2 to 6 microns; and each of the nano features have a mean spacing between about 5 to 12 microns, a maximum peak-to-valley height between about 0.3 to 1.3 microns, and an average amplitude between about 0.03 to 0.06 microns. 
     
     
         14 . The interbody spinal implant of  claim 9 , wherein the substantially hollow center is surrounded by internal surfaces of the body comprising a second graft contact surface comprising micro features and nano features. 
     
     
         15 . The implant of  claim 14 , wherein each of the micro features of the second graft contact surface have a mean spacing between about 20 to 400 microns, a maximum peak-to-valley height between about 2 to 40 microns, and an average amplitude between about 1 to 20 microns, and each of the nano features of the second graft contact surface have a mean spacing between about 0.5 to 20 microns, a maximum peak-to-valley height between about 0.2 to 2 microns, and an average amplitude between about 0.1 to 1 microns. 
     
     
         16 . The implant of  claim 14 , wherein each of the micro features of the second graft contact surface have a mean spacing between about 100 to 300 microns, a maximum peak-to-valley height between about 2 to 20 microns, and an average amplitude between about 4 to 10 microns, and each of the nano features of the second graft contact surface have a mean spacing between about 1 to 15 microns, a maximum peak-to-valley height between about 0.2 to 1.8 microns, and an average amplitude between about 0.01 to 1 microns. 
     
     
         17 . The implant of  claim 14 , wherein each of the micro features of the second graft contact surface have a mean spacing between about 200 to 250 microns, a maximum peak-to-valley height between about 9 to 13 microns, and an average amplitude between about 2 to 6 microns; and each of the nano features of the second graft contact surface have a mean spacing between about 5 to 12 microns, a maximum peak-to-valley height between about 0.3 to 1.3 microns, and an average amplitude between about 0.03 to 0.06 microns. 
     
     
         18 . An implant, comprising a body that is generally rectangular-shaped in transverse cross section and comprises a top surface, a bottom surface, opposing lateral sides, opposing anterior and posterior portions, a substantially hollow center, a sharp edge on the top surface and on the bottom surface for digging into vertebral end plate bone and resisting expulsion of the implant from the intervertebral space, and a single vertical aperture extending from the top surface to the bottom surface, having maximum width at its center, and defining a transverse rim on the top surface and on the bottom surface, said transverse rim having variable width or thickness and at least a portion with an integration surface comprising macro features, micro features, and nano features, wherein the opposing lateral sides and the opposing anterior and posterior portions include a substantially smooth surface comprising nano features. 
     
     
         19 . The implant of  claim 18 , wherein the body comprises a metal. 
     
     
         20 . The implant of  claim 19 , wherein the metal comprises titanium or an alloy thereof. 
     
     
         21 . The implant of  claim 18 , wherein the junction of the posterior portion and the lateral sides is rounded. 
     
     
         22 . The implant of  claim 18 , wherein the body comprises at least one transverse aperture extending through each of the opposing lateral sides and which is in communication with the substantially hollow center. 
     
     
         23 . The implant of  claim 18 , wherein the body comprises a lordotic angle. 
     
     
         24 . The implant of  claim 18 , wherein the single vertical aperture is surrounded by internal surfaces of the body comprising a first graft contact surface comprising micro features and nano features. 
     
     
         25 . The interbody spinal implant of  claim 18 , wherein the integration surface comprises a roughness average amplitude, Ra, of about 8 to 200 microns, and the substantially smooth surface comprises a roughness average amplitude, Ra, of about 0.01 to 2 microns. 
     
     
         26 . The implant of  claim 18 , wherein the macro features have a mean spacing between about 400 to 2000 microns, a maximum peak-to-valley height between about 40 to 500 microns, and an average amplitude between about 20 to 200 microns; the micro features have a mean spacing between about 20 to 400 microns, a maximum peak-to-valley height between about 2 to 40 microns, and an average amplitude between about 1 to 20 microns; and each of the nano features have a mean spacing between about 0.5 to 20 microns, a maximum peak-to-valley height between about 0.2 to 2 microns, and an average amplitude between about 0.1 to 1 microns. 
     
     
         27 . The implant of  claim 18 , wherein the macro features have a mean spacing between about 750 to 1750 microns, a maximum peak-to-valley height between about 150 to 400 microns, and an average amplitude between about 50 to 150 microns; the micro features have a mean spacing between about 100 to 300 microns, a maximum peak-to-valley height between about 2 to 20 microns, and an average amplitude between about 4 to 10 microns; and each of the nano features have a mean spacing between about 1 to 15 microns, a maximum peak-to-valley height between about 0.2 to 1.8 microns, and an average amplitude between about 0.01 to 1 microns. 
     
     
         28 . The implant of  claim 18 , wherein the macro features have a mean spacing between about 1000 to 1500 microns, a maximum peak-to-valley height between about 250 to 300 microns, and an average amplitude between about 100 to 125 microns; the micro features have a mean spacing between about 200 to 250 microns, a maximum peak-to-valley height between about 9 to 13 microns, and an average amplitude between about 2 to 6 microns; and each of the nano features have a mean spacing between about 5 to 12 microns, a maximum peak-to-valley height between about 0.3 to 1.3 microns, and an average amplitude between about 0.03 to 0.06 microns. 
     
     
         29 . The interbody spinal implant of  claim 24 , wherein the substantially hollow center is surrounded by internal surfaces of the body comprising a second graft contact surface comprising micro features and nano features. 
     
     
         30 . The implant of  claim 29 , wherein each of the micro features of the second graft contact surface have a mean spacing between about 20 to 400 microns, a maximum peak-to-valley height between about 2 to 40 microns, and an average amplitude between about 1 to 20 microns, and each of the nano features of the second graft contact surface have a mean spacing between about 0.5 to 20 microns, a maximum peak-to-valley height between about 0.2 to 2 microns, and an average amplitude between about 0.1 to 1 microns. 
     
     
         31 . The implant of  claim 29 , wherein each of the micro features of the second graft contact surface have a mean spacing between about 100 to 300 microns, a maximum peak-to-valley height between about 2 to 20 microns, and an average amplitude between about 4 to 10 microns, and each of the nano features of the second graft contact surface have a mean spacing between about 1 to 15 microns, a maximum peak-to-valley height between about 0.2 to 1.8 microns, and an average amplitude between about 0.01 to 1 microns. 
     
     
         32 . The implant of  claim 29 , wherein each of the micro features of the second graft contact surface have a mean spacing between about 200 to 250 microns, a maximum peak-to-valley height between about 9 to 13 microns, and an average amplitude between about 2 to 6 microns; and each of the nano features of the second graft contact surface have a mean spacing between about 5 to 12 microns, a maximum peak-to-valley height between about 0.3 to 1.3 microns, and an average amplitude between about 0.03 to 0.06 microns.