Multi-layered prosthetic constructs, kits, and methods

Patent metadata

Field	Value
Publication number	US-9439766-B2
Application number	US-201313867564-A
Country	US
Kind code	B2
Filing date	Apr 22, 2013
Priority date	Apr 23, 2012
Publication date	Sep 13, 2016
Grant date	Sep 13, 2016

Abstract

Multi-layered prosthetic constructs, kits, and methods are disclosed. A prosthetic construct can include a first ceramic component having a first surface, the first ceramic component comprising a first ceramic material, and a second ceramic component having a second surface disposed on the first surface of the first ceramic component, the second ceramic component comprising a second ceramic material. The second ceramic material of the second ceramic component can exert a compressive force on the first ceramic material. A ceramic material of the second ceramic component can include a different coefficient of thermal expansion than a ceramic material of the first ceramic component. Optionally, a ceramic construct can include a ceramic component and a membrane disposed onto and bonded to at least a portion of the ceramic component, the membrane configured to provide fracture reinforcement to the ceramic component.

First claim

What is claimed is:

1. A prosthetic construct configured to replace a portion of a bone joint, the prosthetic construct comprising:
a first ceramic component having an outer surface defining a body of the construct shaped for articulation with a corresponding natural or prosthetic joint construct, the first ceramic component comprising a first ceramic material and the outer surface is formed of the first ceramic material; and
a second ceramic component having an outer joint articulation surface and an inner surface disposed on the outer surface of the first ceramic component, the second ceramic component comprising a second ceramic material and the inner surface is formed of the second ceramic material, wherein the second ceramic material of the second ceramic component includes a higher coefficient of thermal expansion than the first ceramic material of the first ceramic component, and wherein the higher coefficient of thermal expansion of the second ceramic material of the second ceramic component causes the second ceramic component to exert a compressive force on the first ceramic component, independent of external forces on the prosthetic construct.

2. The prosthetic construct of claim 1 , wherein the first and second ceramic components, when combined, increase a strength or toughness of the prosthetic construct or change a failure mode of the prosthetic construct, relative to individual strengths, toughnesses, or failure modes of the first or second ceramic component, when separate.

3. The prosthetic construct of claim 1 , wherein the compressive force is exerted in generally the same direction as an expected clinical load to be exerted on the prosthetic construct.

4. The prosthetic construct of claim 1 , wherein the second ceramic material comprises a different ceramic material than the first ceramic material.

5. The prosthetic construct of claim 1 , wherein the inner surface of the second ceramic component is sized and shaped to receive the outer surface of the first ceramic component.

6. The prosthetic construct of claim 1 , wherein each of the first and second ceramic components include a generally spherical shape, and an outer surface diameter of the generally spherical shape of the first ceramic component is less than an outer surface diameter of the generally spherical shape of the second ceramic component.

7. The prosthetic construct of claim 1 , wherein the compressive force is configured to counteract use-based load tensile clinical load.

8. The prosthetic construct of claim 1 , wherein the second ceramic component is sized and shaped to substantially surround the first ceramic component.

9. The prosthetic construct of claim 1 , wherein the outer joint articulation surface of the second ceramic component includes a convex portion defining an articulating bearing surface sized and shaped for seated engagement with a natural or prosthetic concave cup portion of the corresponding joint construct.

10. The prosthetic construct of claim 1 , further comprising a membrane disposed between the first and second ceramic components, the membrane coupled to a portion of each ceramic component.

11. The prosthetic construct of claim 1 , wherein a ceramic material of each of the first and second ceramic components comprises at least one of alumina (Al 2 O 3 ), zirconia (ZrO 2 ), silica (SiO 2 ), hydroxyapatite (Ca 10 (PO 4 ) 6 (OH) 2 ), titanium nitride (TiN), and silicon nitride (Si 3 N 4 ).

12. The prosthetic construct of claim 1 , wherein the prosthetic construct includes at least a portion of a hip implant.

13. The prosthetic construct of claim 1 , wherein the prosthetic construct includes at least a portion of a distal femoral implant.

Assignees

• Zimmer Inc

Inventors

• Monaghan Matthew E
• Miller David M

Classifications

• A61F2/3859 Primary

  Femoral components · CPC title

• A61F2002/30971

  Laminates, i.e. layered products · CPC title

• A61F2002/30077

  shrinkable · CPC title

• A61F2/3094

  Designing or manufacturing processes · CPC title

• A61F2310/00317

  containing silicon nitride · CPC title