Materials with modified surfaces and methods of manufacturing

Abstract

Various embodiments of surface-modified devices, components, and associated methods of manufacturing are described herein. In one embodiment, an implantable device suitable for being implanted in a patient includes an implantable material having a utile shape and a surface and a modification material deposited on at least a portion of the surface of the implantable material. The modification material has a release rate in an implantation environment in the patient. The modification material at the release rate is effective as bactericidal without being cytotoxic to the patient

I/we claim: 
     
         1 . An implantable device suitable for being implanted in a patient, comprising:
 an implantable material having a utile shape and a surface; and   a modification material deposited on at least a portion of the surface of the implantable material, the modification material having a release rate in an implantation environment in the patient, the modification material at the release rate being effective as a bactericidal without being cytotoxic to the patient, wherein the deposited modification material does not substantially affect a mechanical property of the implantable material, and wherein the deposited modification material has an interfacial shear strength of about 1 MPa to about 30 MPa.   
     
     
         2 . The implantable device of  claim 1  wherein:
 the implantable material includes at least one of a metal, a metal alloy, a metal oxide, a ceramic, an organic salt, or a polymeric material; and 
 the modification material include at least one of silver, gold, zinc oxide, or copper. 
 
     
     
         3 . The implantable device of  claim 1  wherein the modification material includes silver. 
     
     
         4 . The implantable device of  claim 1  wherein:
 the implantable material includes stainless steel; and 
 the modification material include silver. 
 
     
     
         5 . The implantable device of  claim 1  wherein:
 the implantable material includes stainless steel; 
 the modification material include silver; and 
 the deposited silver having a release rate into the implantation environment in the patient, the release rate corresponding to a concentration of silver in the implantation environment effective as a bactericidal without being cytotoxic to the patient. 
 
     
     
         6 . An implantable device suitable for being implanted in a patient, comprising:
 a substrate having a utile shape and a substrate surface, the substrate being constructed from stainless steel; and   a modification material deposited on at least a portion of the substrate surface of the implantable component, wherein:
 the deposited modification material includes silver electroplated onto at least a portion of the substrate surface; 
 the electroplated silver does not vary a mechanical property of the substrate by more than about 10%; 
 the electroplated silver has an interfacial shear strength of about 1 MPa to about 30 MPa on the substrate surface; and 
 the electroplated silver is configured to be released into an implantation environment in the patient at a target release rate resulting in a concentration of silver in the implantation environment to be about 0.01 mg/L to about 30 mg/L. 
   
     
     
         7 . The implantable device of  claim 6  wherein the electroplated silver has a surface area coverage of about 0.1% to about 10% on the substrate surface. 
     
     
         8 . The implantable device of  claim 6  wherein:
 the mechanical property of the substrate includes one of tensile strength, compressive strength, yield strength, Young's modulus, ductility, or toughness; and 
 the electroplated silver does not vary any of the tensile strength, compressive strength, yield strength, Young's modulus, ductility, or toughness of the substrate by more than about 10%. 
 
     
     
         9 . The implantable device of  claim 6  wherein:
 the modification material is a first modification material deposited on a first portion of the component surface; and 
 the implantable device further includes a second modification material deposited on a second portion of the component surface, the second modification material being different than the first modification material. 
 
     
     
         10 . The implantable device of  claim 6  wherein:
 the modification material is a first modification material deposited on a portion of the component surface; and 
 the implantable device further includes a second modification material deposited on the first modification material forming a layered structure on the component surface, the second modification material being different than the first modification material. 
 
     
     
         11 . The implantable device of  claim 6  wherein the substrate is a rod, a nail, a screw, or a plate. 
     
     
         12 . An implantable device suitable for being implanted in a patient, comprising:
 an implantable component having a utile shape and a component surface; and   a modification material deposited on at least a portion of the component surface of the implantable component, wherein:
 the deposited modification material does not vary a mechanical property of the implantable component by more than about 10%; 
 the deposited modification material has an interfacial shear strength of about 1 MPa to about 30 MPa on the component surface; and 
 the deposited modification material has a release rate in an implantation environment in the patient, the release rate resulting in a concentration of the modification material in the implantation environment to be about 0.01 mg/L to about 30 mg/L. 
   
     
     
         13 . The implantable device of  claim 12  wherein:
 the implantable material includes at least one of a metal, a metal alloy, a metal oxide, a ceramic, an organic salt, or a polymeric material; and 
 the modification material include at least one of silver, gold, zinc oxide, or copper. 
 
     
     
         14 . The implantable device of  claim 12  wherein the modification material is silver, and wherein the deposited silver on the component surface has an interfacial shear strength of about 1 MPa to about 30 MPa. 
     
     
         15 . The implantable device of  claim 12  wherein:
 the implantable component includes stainless steel with a stainless steel surface; 
 the modification material includes silver electroplated onto the stainless steel surface, and 
 the silver electroplated on the stainless steel surface has an interfacial shear strength of about 1 MPa to about 30 MPa. 
 
     
     
         16 . The implantable device of  claim 12  wherein the deposited modification material has a surface area coverage of about 0.1% to about 10% on the component surface. 
     
     
         17 . The implantable device of  claim 12  wherein the deposited modification material forms one of a circle, a square, a honeycomb, or a weave pattern on the component surface. 
     
     
         18 . The implantable device of  claim 12  wherein:
 the mechanical property of the implantable component includes one of tensile strength, compressive strength, yield strength, Young's modulus, ductility, or toughness; and 
 the deposited modification material does not vary the mechanical property of the implantable component by more than about 5%. 
 
     
     
         19 . The implantable device of  claim 12  wherein:
 the modification material is a first modification material deposited on a first portion of the component surface; and 
 the implantable device further includes a second modification material deposited on a second portion of the component surface, the second modification material being different than the first modification material. 
 
     
     
         20 . The implantable device of  claim 12  wherein:
 the modification material is a first modification material deposited on a portion of the component surface; and 
 the implantable device further includes a second modification material deposited on the first modification material forming a layered structure on the component surface, the second modification material being different than the first modification material.