Methods for applying a bioactive coating onto a surface of an implant

Abstract

Devices, systems, and methods for applying a bioactive coating to an exterior surface of an implant are disclosed. In some embodiments, the bioactive coating may be applied to the surfaces of the implant within the operating room at the time of implantation. In one embodiment, the implant may be a temporary spacer used to temporary replace an implant in a patient suffering from an infection. The temporary spacer being, for example, an antibacterial material for fighting the infection. In some embodiments, the method includes providing a mold of the implant, and providing the bioactive coating within the mold. The method may further include inserting the implant into the mold so that the exterior surface of the implant contacts the bioactive coating, and then removing the implant from the mold.

What is claimed is: 
     
         1 . A method for applying a bioactive coating to an exterior surface of an implant within an operating room at a time of implantation, the method comprising:
 providing a mold having an interior cavity;   positioning the bioactive coating within the interior cavity of the mold;   inserting the implant into the interior cavity of the mold so that the exterior surface of the implant contacts the bioactive coating; and   removing the implant from the interior cavity of the mold along with the bioactive coating adhered thereto.   
     
     
         2 . The method of  claim 1 , further comprising forming a plurality of recesses in the exterior surface of the implant prior to inserting the implant into the mold. 
     
     
         3 . The method of  claim 1 , wherein the implant is a temporary spacer. 
     
     
         4 . The method of  claim 3 , wherein the spacer is formed from a bone cement and the bioactive coating is an antibiotic coating for fighting an infection. 
     
     
         5 . The method of  claim 1 , wherein positioning the bioactive coating within the mold comprises depositing an antibiotic coating within the interior cavity of the mold. 
     
     
         6 . The method of  claim 5 , further comprising providing one or more surface features on an internal surface of the interior cavity of the mold to enable positioning of the implant within the interior cavity of the mold. 
     
     
         7 . The method of  claim 1 , further comprising:
 wetting the exterior surface of the implant;   inserting the implant into a powder including bioactive coating; and   inserting the implant and powder into saline or water to form a gel coating.   
     
     
         8 . The method of  claim 1 , wherein the mold is part of packaging materials used for delivering the implant. 
     
     
         9 . A method for applying a bioactive coating to an exterior surface of an implant within an operating room at a time of implantation, the method comprising:
 inserting the implant within an interior cavity of a mold;   injecting the bioactive coating into a space between the exterior surface of the implant and an interior surface defining the interior cavity of the mold; and   removing the implant and the bioactive coating adhered thereto from the interior cavity of the mold.   
     
     
         10 . The method of  claim 9 , wherein the implant is a temporary spacer formed from a bone cement and the bioactive coating is an antibiotic coating for fighting an infection. 
     
     
         11 . The method of  claim 9 , wherein injecting the bioactive coating within the interior cavity of the mold comprises injecting an antibiotic coating within the interior cavity of the mold. 
     
     
         12 . The method of  claim 9 , further comprising providing one or more surface features on an internal surface of the interior cavity of the mold to enable positioning of the implant within the interior cavity of the mold. 
     
     
         13 . The method of  claim 9 , further comprising coating the implant with a liquid prior to inserting the implant into the interior cavity of the mold, wherein the bioactive coating is a powdered antibiotic, and wherein the liquid causes the powdered antibiotic to adhere to the exterior surface of the implant. 
     
     
         14 . The method of  claim 9 , further comprising:
 coating the implant with a de-hydrated hydrogel; and   immersing the implant in a hydrating solution containing the bioactive coating to form a bioactive containing hydrogel on the exterior surface of the implant.   
     
     
         15 . The method of  claim 14 , wherein coating the implant with a de-hydrated hydrogel comprises wrapping the implant in a tape comprising the de-hydrated hydrogel. 
     
     
         16 . A method for implanting a temporary spacer into a patient suffering from an infection, the method comprising:
 removing a previously inserted implant from a patient;   providing a temporary spacer;   coating the temporary spacer in an operating room with a bioactive coating; and   implanting the temporary spacer into the patient.   
     
     
         17 . The method of  claim 16 , wherein the spacer is formed from a bone cement and the bioactive coating is an antibiotic coating for fighting an infection. 
     
     
         18 . The method of  claim 17 , wherein the antibiotic coating leaches out of the spacer over a period of time. 
     
     
         19 . The method of  claim 16 , wherein the temporary spacer and the bioactive coating are arranged and configured to promote better adhesion between the bioactive coating and the spacer and to provide better elution of the bioactive coating. 
     
     
         20 . The method of  claim 16 , wherein the temporary spacer includes one or more pockets formed therein, the pockets containing an antibiotic coating.