Stent device for spinal fusion

Abstract

A bone implant for at least partial insertion into a bone and/or cartilage. The bone implant is at least partially formed of a metal alloy of at least about 90 wt. % of a solid solution or a rhenium and molybdenum alloy.

1 - 36 . (canceled) 
     
     
         37 . A bone implant at least partially formed of metal coated material that includes a core material and a metal coating; said core material formed of a different material than said metal coating; said core material including one or more materials selected from the group consisting of metal alloy, ceramic or composite material; said metal coating form of a metal alloy selected from the group consisting of a) at least about 90 wt. % of a solid solution or rhenium and molybdenum and one or more alloying agents selected from the group consisting of calcium, carbon, chromium, cobalt, copper, gold, hafnium, iron, lead, magnesium, nickel, niobium, osmium, platinum, rare earth metal, silver, tantalum, technetium, titanium, tungsten, vanadium, yttrium, zinc and zirconium, or b) tungsten and copper, and wherein said tungsten and copper constitute at least 90 wt. % of said metal alloy; said core material of said metal coated material constituting 50-99% of an overall cross-section of said metal coated material. 
     
     
         38 . The bone implant as defined in  claim 37 , wherein a hardness of said core material is less than a hardness of said metal coating; said core material has a hardness of 250 Vickers to 550 Vickers; said metal coating has a hardness of 350 Vickers to 1000 Vickers. 
     
     
         39 . The bone implant as defined in  claim 37 , wherein said metal alloy of said metal coating includes at least 95 wt. % of a solid solution of a rhenium and molybdenum and one or more alloying agents selected from the group consisting of chromium, cobalt, copper, hafnium, nickel, niobium, osmium, rare earth metal, tantalum, technetium, titanium, tungsten, vanadium, yttrium, and zirconium. 
     
     
         40 . The bone implant as defined in  claim 38 , wherein said metal alloy of said metal coating includes at least 95 wt. % of a solid solution of a rhenium and molybdenum and one or more alloying agents selected from the group consisting of chromium, cobalt, copper, hafnium, nickel, niobium, osmium, rare earth metal, tantalum, technetium, titanium, tungsten, vanadium, yttrium, and zirconium. 
     
     
         41 . The bone implant as defined in  claim 39 , wherein said metal alloy of said metal coating includes at least 95 wt. % of a solid solution of a rhenium and molybdenum and chromium. 
     
     
         42 . The bone implant as defined in  claim 40 , wherein said metal alloy of said metal coating includes at least 95 wt. % of a solid solution of a rhenium and molybdenum and chromium. 
     
     
         43 . The bone implant as defined in  claim 37 , wherein said metal alloy of said metal coating includes at least 95 wt. % of a solid solution of tungsten and copper. 
     
     
         44 . The bone implant as defined in  claim 38 , wherein said metal alloy of said metal coating includes at least 95 wt. % of a solid solution of tungsten and copper. 
     
     
         45 . The bone implant as defined in  claim 37 , wherein said metal alloy of said metal coating has a controlled amount of nitrogen, oxygen and carbon so as to reduce micro-cracking in said metal alloy; a nitrogen content of said metal alloy less than a combined content of oxygen and carbon in said metal alloy; said metal alloy includes an oxygen to nitrogen atomic ratio of at least about 1.2:1; said metal alloy includes a carbon to nitrogen atomic ratio of at least about 2:1. 
     
     
         46 . The bone implant as defined in  claim 37 , wherein an outer surface of said metal alloy of said metal coating has an outer layer formed by a gas nitriding process, a salt-bath nitriding process, or a plasma nitriding process, wherein said nitride surface layer results in enhanced wear resistance properties to said rhenium and molybdenum alloy as compared to a similar rhenium and molybdenum alloy absent said nitride surface layer. 
     
     
         47 . The bone implant as defined in  claim 37 , wherein said metal alloy of said metal coating is at least partially formed from powdered particles of said metal alloy; an average particle size of said powder particles is less than 74 microns. 
     
     
         48 . The bone implant as defined in  claim 37 , wherein said bone implant is in the form of a rod, nail, screw, post, a bone plate or an implant that repairs and/or supports a bone. 
     
     
         49 . A method of at least partially inserting an implant into a bone and/or cartilage of a spinal column comprising:
 a) providing a bone implant as defined in  claim 37 ; and,   b) at least partially inserting said bone implant into said bone and/or cartilage of a spinal column.   
     
     
         50 . A medical device at least partially formed of metal material; said medical device includes b) a bone plate or b) an implant that repairs and/or supports a bone; said metal material is partially or fully formed of a metal alloy; said metal alloy includes i) at least about 90 wt. % of a solid solution or rhenium and molybdenum and one or more alloying agents selected from the group consisting of calcium, carbon, chromium, cobalt, copper, gold, hafnium, iron, lead, magnesium, nickel, niobium, osmium, platinum, rare earth metal, silver, tantalum, technetium, titanium, tungsten, vanadium, yttrium, zinc and zirconium, or ii) tungsten and copper, and wherein said tungsten and copper constitute at least 90 wt. % of said metal alloy; said metal alloy has a controlled amount of nitrogen, oxygen and carbon so as to reduce micro-cracking in said metal alloy; a nitrogen content of said metal alloy less than a combined content of oxygen and carbon in said metal alloy; said metal alloy includes an oxygen to nitrogen atomic ratio of at least about 1.2:1; said metal alloy includes a carbon to nitrogen atomic ratio of at least about 2:1. 
     
     
         51 . The medical device as defined in  claim 50 , wherein said metal material is formed of multiple metal layers; one layer is formed of said metal alloy; one other layer is formed of a) titanium alloy, b) chromium alloy, c) chromium-cobalt alloy, or d) stainless-steel. 
     
     
         52 . The medical device as defined in  claim 50 , wherein said metal alloy of said metal coating includes at least 95 wt. % of a solid solution of a rhenium and molybdenum and one or more alloying agents selected from the group consisting of chromium, cobalt, copper, hafnium, nickel, niobium, osmium, rare earth metal, tantalum, technetium, titanium, tungsten, vanadium, yttrium, and zirconium. 
     
     
         53 . The medical device as defined in  claim 51 , wherein said metal alloy of said metal coating includes at least 95 wt. % of a solid solution of a rhenium and molybdenum and one or more alloying agents selected from the group consisting of chromium, cobalt, copper, hafnium, nickel, niobium, osmium, rare earth metal, tantalum, technetium, titanium, tungsten, vanadium, yttrium, and zirconium. 
     
     
         54 . The medical device as defined in  claim 50 , wherein said metal alloy of said metal coating includes at least 95 wt. % of a solid solution of a rhenium and molybdenum and chromium. 
     
     
         55 . The medical device as defined in  claim 53 , wherein said metal alloy of said metal coating includes at least 95 wt. % of a solid solution of a rhenium and molybdenum and chromium. 
     
     
         56 . The medical device as defined in  claim 50 , wherein said metal alloy of said metal coating includes at least 95 wt. % of a solid solution of tungsten and copper. 
     
     
         57 . The medical device as defined in  claim 51 , wherein said metal alloy of said metal coating includes at least 95 wt. % of a solid solution of tungsten and copper. 
     
     
         58 . The medical device as defined in  claim 51 , wherein said one layer or said one other layer forms a core of said metal material; said core constituting 50-99% of an overall cross-section of said metal material. 
     
     
         59 . The medical device as defined in  claim 55 , wherein said one layer or said one other layer forms a core of said metal material; said core constituting 50-99% of an overall cross-section of said metal material. 
     
     
         60 . The medical device as defined in  claim 57 , wherein said one layer or said one other layer forms a core of said metal material; said core constituting 50-99% of an overall cross-section of said metal material. 
     
     
         61 . A method for forming a spinal rod that includes a metal coated rod comprising the steps of:
 a) providing a rod core; said rod core is formed of a metal alloy that includes at least about 60 wt. % of a solid solution of rhenium and molybdenum alloy; said metal alloy includes at least about 20 wt. % rhenium and at least about 20 wt. % molybdenum;   b) providing coating material; said coating material is formed of a different material from said metal alloy used to form said rod core; said coating material is selected from form the group consisting of iron, cobalt-chromium, titanium alloy, stainless steel, rhenium alloy, molybdenum alloy, polymer material, and ceramic material; and   c) coating said coating material on at least a portion of an outer surface of said rod core to formed said metal coated rod; said rod core constitutes at least 50% of an overall cross-section of said metal coated rod.   
     
     
         62 . The method as defined in  claim 61 , wherein said metal alloy includes wt. % rhenium and 40-60 wt. % molybdenum. 
     
     
         63 . The method as defined in  claim 61 , wherein said content of said rhenium and molybdenum in said metal alloy constitutes at least 95 wt. % of said metal alloy; said metal alloy includes one or more metals selected from the group consisting of copper, manganese, silicon, and titanium. 
     
     
         64 . The method as defined in  claim 62 , wherein said content of said rhenium and molybdenum in said metal alloy constitutes at least 95 wt. % of said metal alloy; said metal alloy includes one or more metals selected from the group consisting of copper, manganese, silicon, and titanium. 
     
     
         65 . The method as defined in  claim 61 , wherein said coating material is selected from the group consisting of titanium, titanium alloy, cobalt-chromium alloy, and stainless steel. 
     
     
         66 . The method as defined in  claim 64 , wherein said coating material is selected from the group consisting of titanium, titanium alloy, cobalt-chromium alloy, and stainless steel. 
     
     
         67 . The method as defined in  claim 61 , wherein said rod core constitutes at least 90% of an overall cross-section of said metal coated rod. 
     
     
         68 . The method as defined in  claim 66 , wherein said rod core constitutes at least 90% of an overall cross-section of said metal coated rod. 
     
     
         69 . The method as defined in  claim 61 , further including the steps of:
 drawing down said outer cross-sectional area of said metal coated rod by a reducing mechanism;   annealing said metal coated rod at an annealing temperature in an oxygen reducing environment or inert environment after said rod or tube has been drawn down; and,   cooling said annealed metal coated rod.   
     
     
         70 . The method as defined in  claim 68 , further including the steps of:
 drawing down said outer cross-sectional area of said metal coated rod by a reducing mechanism;   annealing said metal coated rod at an annealing temperature in an oxygen reducing environment or inert environment after said rod or tube has been drawn down; and,   cooling said annealed metal coated rod.   
     
     
         71 . The method as defined in  claim 61 , wherein at least one region of an outer surface of said metal coated rod includes at least one biological agent. 
     
     
         72 . The method as defined in  claim 68 , wherein at least one region of an outer surface of said metal coated rod includes at least one biological agent. 
     
     
         73 . The method as defined in  claim 61 , wherein at least one region of said metal coated rod includes at least one polymer; at least one said polymer at least partially coats, encapsulates, or combinations thereof, at least one biological agent. 
     
     
         74 . The method as defined in  claim 68 , wherein at least one region of said metal coated rod includes at least one polymer; at least one said polymer at least partially coats, encapsulates, or combinations thereof, at least one biological agent. 
     
     
         75 . A spinal rod that includes a metal coated rod comprising:
 a) a rod core; said rod core is formed of a metal alloy that includes at least about 60 wt. % of a solid solution of rhenium and one or more metals selected from the group consisting of molybdenum, calcium, chromium, cobalt, copper, gold, hafnium, iron, lead, magnesium, nickel, niobium, osmium, platinum, rare earth metals, rhenium, silver, tantalum, technetium, titanium, tungsten, vanadium, yttrium, zinc, and zirconium; said metal alloy includes at least about 20 wt. % rhenium; and   b) a coating material; said coating material is formed of a different material from said metal alloy used to form said rod core; said coating material is selected from form the group consisting of iron, cobalt-chromium, titanium alloy, stainless steel, rhenium alloy, molybdenum alloy, polymer material, and ceramic material; and   wherein said coating material is coated on at least a portion of an outer surface of said rod core to formed said metal coated rod; and   wherein said rod core constitutes at least 50% of an overall cross-section of said metal coated rod.   
     
     
         76 . The spinal rod as defined in  claim 75 , wherein said metal alloy includes 40-60 wt. % rhenium and 40-60 wt. % molybdenum. 
     
     
         77 . The spinal rod as defined in  claim 75 , wherein said content of said rhenium and molybdenum in said metal alloy constitutes at least 95 wt. % of said metal alloy; said metal alloy includes one or more metals selected from the group consisting of copper, manganese, silicon, and titanium. 
     
     
         78 . The spinal rod as defined in  claim 76 , wherein said content of said rhenium and molybdenum in said metal alloy constitutes at least 95 wt. % of said metal alloy; said metal alloy includes one or more metals selected from the group consisting of copper, manganese, silicon, and titanium. 
     
     
         79 . The spinal rod as defined in  claim 75 , wherein said coating material is selected from the group consisting of titanium, titanium alloy, cobalt-chromium alloy, and stainless steel. 
     
     
         80 . The spinal rod as defined in  claim 78 , wherein said coating material is selected from the group consisting of titanium, titanium alloy, cobalt-chromium alloy, and stainless steel. 
     
     
         81 . The spinal rod as defined in  claim 75 , wherein said rod core constitutes at least 90% of an overall cross-section of said metal coated rod. 
     
     
         82 . The spinal rod as defined in  claim 80 , wherein said rod core constitutes at least 90% of an overall cross-section of said metal coated rod. 
     
     
         83 . The spinal rod as defined in  claim 75 , wherein at least one region of an outer surface of said metal coated rod includes at least one biological agent. 
     
     
         84 . The spinal rod as defined in  claim 82 , wherein at least one region of an outer surface of said metal coated rod includes at least one biological agent. 
     
     
         85 . The spinal rod as defined in  claim 75 , wherein at least one region of said metal coated rod includes at least one polymer; at least one said polymer at least partially coats, encapsulates, or combinations thereof, at least one biological agent. 
     
     
         86 . The spinal rod as defined in  claim 82 , wherein at least one region of said metal coated rod includes at least one polymer; at least one said polymer at least partially coats, encapsulates, or combinations thereof, at least one biological agent. 
     
     
         87 . The spinal rod as defined in  claim 75 , wherein said coating material includes titanium. 
     
     
         88 . The spinal rod as defined in  claim 86 , wherein said coating material includes titanium.