Mobile bearing tibial base prosthetic devices employing oxidized zirconium surfaces

• US 20040034432A1
• Filed: 08/08/2003
• Published: 02/19/2004
• Est. Priority Date: 02/11/2002
• Status: Abandoned Application

• Current Assignee: Smith & Nephew Incorporated (Smith & Nephew PLC)
• Original Assignee: Smith & Nephew Incorporated (Smith & Nephew PLC)
• Inventors: Carson, Christopher P., Hunter, Gordon, Hughes, Dean, Gupta, Harsh
• Application Number:
  US10/637,975
• Publication Number:
  US 20040034432A1
• Time in Patent Office: Days
• US Class Current: 623/20.28
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/3868 with sliding tibial bearing
• CPC Class Codes: A61F 2/3886 for stabilising knees against anterior or lateral dislocations
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2002/30133 kidney-shaped or bean-shaped
• CPC Class Codes: A61F 2002/30326 differing in height or in length
• CPC Class Codes: A61F 2002/30383 made by laterally inserting a protrusion, e.g. a rib into a complementarily-shaped groove
• CPC Class Codes: A61F 2002/30507 using a threaded locking member, e.g. a locking screw or a set screw
• CPC Class Codes: A61F 2002/30518 with possibility of relative movement between the prosthetic parts
• CPC Class Codes: A61F 2002/30604 modular
• CPC Class Codes: A61F 2002/30841 Sharp anchoring protrusions for impaction into the bone, e.g. sharp pins, spikes
• CPC Class Codes: A61F 2002/30878 with non-sharp protrusions, for instance contacting the bone for anchoring, e.g. keels, pegs, pins, posts, shanks, stems, struts
• CPC Class Codes: A61F 2002/30892 parallel
• CPC Class Codes: A61F 2002/30909 Nets
• CPC Class Codes: A61F 2002/30922 Hardened surfaces
• CPC Class Codes: A61F 2002/30934 Special articulating surfaces
• CPC Class Codes: A61F 2220/0025 Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: A61F 2230/0015 Kidney-shaped, e.g. bean-shaped
• CPC Class Codes: A61F 2250/0037 differing in height or in length
• CPC Class Codes: A61F 2310/00089 : Zirconium or Zr-based alloys
• CPC Class Codes: A61F 2310/00634 : Coating made of zirconium oxide or hydroxides
• CPC Class Codes: A61F 2310/0064 : Coating made of niobium oxide or hydroxides
• CPC Class Codes: A61F 2310/00652 : Coating made of hafnium oxide or hydroxides
• CPC Class Codes: A61F 2310/00658 : Coating made of tantalum oxide or hydroxides
• CPC Class Codes: A61F 2310/00892 : Coating made of zirconium nitride
• CPC Class Codes: A61L 2430/24 : for joint reconstruction
• CPC Class Codes: A61L 27/16 : obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: A61L 27/306 : Other specific inorganic materials not covered by A61L27/303 - A61L27/32
• CPC Class Codes: C08L 23/06 : Polyethene
• CPC Class Codes: C23C 8/10 : Oxidising

Abstract

An orthopedic implant with a diffusion-hardened surface on non-load bearing areas of the implant for interaction with non-load bearing surfaces of a polymeric bio-compatible material, such as UHMWPE (ultra-high molecular weight polyethylene). The orthopedic implant is a mobile-bearing knee prosthetic and system where a coating of oxidized zirconium is formed on the post of the tibial tray of the prosthetic for interaction with an opening of a polymeric tibial insert. The diffusion-hardened surface of the orthopedic implant provides a strengthened post and reduction in wear in the opening of the polymeric insert.

Claims

1. A mobile bearing knee system comprising:

a tibial tray having a distal surface adapted to be surgically implanted on a patient'"'"'s surgically cut proximal tibia, the tibial tray having a proximal surface with a post extending up from the proximal surface of the tray; and

a tibial insert having a proximal surface that is shaped to engage a femoral component, the insert having a distal surface that fits against and articulates with the proximal surface of the tibial tray;

wherein the post having a diffusion-hardened surface along at least a portion of the post where the post communicates with the tibial insert.

2. The mobile bearing knee system of claim 1, wherein the diffusion-hardened surface of the post is a thin coating of blue-black or black zirconium oxide.

3. The mobile bearing knee system of claim 1, wherein the diffusion-hardened surface of the post is a thin coating of oxidized metal selected from one or more metals from the group consisting of hafnium, zirconium, niobium and tantalum.

4. The mobile bearing knee system of claim 1, wherein the polymeric biocompatible material is ultra-high molecular weight polyethylene.

5. The mobile bearing knee system of claim 1, wherein the distal surface of the tibial tray having a stem for implantation to the patient'"'"'s proximal tibia.

6. The mobile bearing knee system of claim 1, wherein the distal surface of the tibial tray having at least one spike for implantation to the patient'"'"'s proximal tibia.

7. The mobile bearing knee system of claim 1, wherein the proximal surface of the insert having one or more concavities for articulating with the femoral component.

8. The mobile bearing knee system of claim 1, wherein all or part of the post is separable from the tray.

9. The mobile bearing knee system of claim 1, further comprising a locking plug member that fits a socket on the post.

10. The mobile bearing knee system of claim 9, wherein the insert having a slot on the distal surface of the insert, an opening on the proximal surface of the insert that communicates with the slot, and wherein the locking plug member can access the post from the proximal surface of the insert via the opening.

11. The mobile bearing knee system of claim 10, wherein the slot has a generally cylindrically-shaped section that communicates with the proximal surface of the insert.

12. The mobile bearing knee system of any one of claims 1-11, wherein the proximal surface of the tibial tray having a first diffusion-hardened surface along at least a portion of the proximal surface of the tray.

13. The mobile bearing knee system of claim 12, wherein the diffusion-hardened surface of the proximal surface of the tibial tray is a thin coating of blue-black or black zirconium oxide.

14. The mobile bearing knee system of claim 12, wherein the diffusion-hardened surface of the proximal surface of the tibial tray is a thin coating of oxidized metal selected from one or more metals from the group consisting of hafnium, zirconium, niobium and tantalum.

15. The mobile bearing knee system of claim 1, wherein the post is partially spherical, elliptical, conical, or cylindrical in shape.

16. The mobile bearing knee system of claim 1, wherein the proximal surface having a diffusion-hardened surface along at least a portion of the proximal surface.

17. A mobile bearing knee system comprising:

a tibial tray having a distal surface adapted to be surgically implanted on a patient'"'"'s surgically cut proximal tibia, the tibial tray having a proximal surface having a slot; and

a tibial insert having a proximal surface that is shaped to engage a femoral component and a distal surface that fits against and articulates with the proximal surface of the tibial tray, the tibial insert having a proximal surface with a post that communicates with the slot;

wherein the slot having a diffusion-hardened surface along at least a portion of the slot where the post communicates with the slot.

18. The mobile bearing knee system of claim 17, wherein the diffusion-hardened surface of the slot is a thin coating of blue-black or black zirconium oxide.

19. The mobile bearing knee system of claim 17, wherein the diffusion-hardened surface of the slot is a thin coating of oxidized metal selected from one or more metals from the group consisting of hafnium, zirconium, niobium and tantalum.

20. The mobile bearing knee system of claim 17, wherein the polymeric biocompatible material is ultra-high molecular weight polyethylene.

21. The mobile bearing knee system of claim 17, wherein the distal surface of the tibial tray having a stem for implantation to the patient'"'"'s proximal tibia.

22. The mobile bearing knee system of claim 17, wherein the distal surface of the tibial tray having at least one spike for implantation to the patient'"'"'s proximal tibia.

23. The mobile bearing knee system of claim 17, wherein the proximal surface of the insert having one or more concavities for articulating with the femoral component.

24. The mobile bearing knee system of claim 17, wherein the post is partially spherical, elliptical, conical, or cylindrical in shape.

25. A mobile bearing knee system comprising:

a tibial tray having a distal surface adapted to be surgically implanted on a patient'"'"'s surgically cut proximal tibia and a proximal surface having at least one rail on the proximal surface; and

a tibial insert having a proximal surface that is shaped to engage a femoral component and a distal surface that fits against and articulates with the proximal surface of the tibial tray, the tibial insert having a proximal surface with at least one channel that communicates with the at least one rail;

wherein the rail having a diffusion-hardened surface along at least a portion of the rail where the rail communicates with the channel.

26. The mobile bearing knee system of claim 25, wherein the diffusion-hardened surface of the rail is a thin coating of blue-black or black zirconium oxide.

27. The mobile bearing knee system of claim 25, wherein the diffusion-hardened surface of the rail is a thin coating of oxidized metal selected from one or more metals from the group consisting of hafnium, zirconium, niobium and tantalum.

28. The mobile bearing knee system of claim 25, wherein the polymeric biocompatible material is ultra-high molecular weight polyethylene.

29. The mobile bearing knee system of claim 25, wherein the distal surface of the tibial tray having a stem for implantation to the patient'"'"'s proximal tibia.

30. The mobile bearing knee system of claim 25, wherein the distal surface of the tibial tray having at least one spike for implantation to the patient'"'"'s proximal tibia.

31. The mobile bearing knee system of claim 25, wherein the proximal surface of the insert having one or more concavities for articulating with the femoral component.

32. The mobile bearing knee system of claim 25, wherein all of the surface of the at least one rail has a diffusion-hardened surface.

33. A mobile bearing knee system comprising:

a tibial tray having a distal surface adapted to be surgically implanted on a patient'"'"'s surgically cut proximal tibia and a proximal surface having at least one channel; and

a tibial insert having a proximal surface that is shaped to engage a femoral component and a distal surface that fits against and articulates with the proximal surface of the tibial tray, the tibial insert having a proximal surface with at least one rail that communicates with the at least one channel;

wherein the at least one channel having a diffusion-hardened surface along at least a portion of the channel where the rail communicates with the channel.

34. The mobile bearing knee system of claim 33, wherein the diffusion-hardened surface of the channel is a thin coating of blue-black or black zirconium oxide.

35. The mobile bearing knee system of claim 33, wherein the diffusion-hardened surface of the channel is a thin coating of oxidized metal selected from one or more metals from the group consisting of hafnium, zirconium, niobium and tantalum.

36. The mobile bearing knee system of claim 33, wherein the polymeric bio-compatible material is ultra-high molecular weight polyethylene.

37. The mobile bearing knee system of claim 33, wherein the distal surface of the tibial tray having a stem for implantation to the patient'"'"'s proximal tibia.

38. The mobile bearing knee system of claim 33, wherein the distal surface of the tibial tray having at least one spike for implantation to the patient'"'"'s proximal tibia.

39. The mobile bearing knee system of claim 33, wherein the proximal surface of the insert having one or more concavities for articulating with the femoral component.

40. The mobile bearing knee system of claim 33, wherein all of the surface of the at least one channel has a diffusion-hardened surface.

41. A mobile bearing knee system comprising:

a tibial tray having a distal surface adapted to be surgically implanted on a patient'"'"'s surgically cut proximal tibia and a proximal surface having a shaped circular surface;

a tibial insert having a proximal surface that is shaped to engage a femoral component and a distal surface that fits against and articulates with the proximal surface of the tibial tray, the tibial insert having a shaped circular surface that communicates with the tibial tray'"'"'s shaped circular surface;

wherein the tibial tray'"'"'s shaped circular surface having a diffusion-hardened surface.

42. The mobile bearing knee system of claim 41, wherein the diffusion-hardened surface is a thin coating of blue-black or black zirconium oxide.

43. The mobile bearing knee system of claim 41, wherein the diffusion-hardened surface is a thin coating of oxidized metal selected from one or more metals from the group consisting of hafnium, zirconium, niobium and tantalum.

44. The mobile bearing knee system of claim 41, wherein the polymeric bio-compatible material is ultra-high molecular weight polyethylene.

45. The mobile bearing knee system of claim 41, wherein the distal surface of the tibial tray having a stem for implantation to the patient'"'"'s proximal tibia.

46. The mobile bearing knee system of claim 41, wherein the distal surface of the tibial tray having at least one spike for implantation to the patient'"'"'s proximal tibia.

47. The mobile bearing knee system of claim 41, wherein the proximal surface of the insert having one or more concavities for articulating with the femoral component.