Bi-polar hip prosthetic devices employing diffusion-hardened surfaces

• US 20040122524A1
• Filed: 12/18/2002
• Published: 06/24/2004
• Est. Priority Date: 12/18/2002
• Status: Abandoned Application

• Current Assignee: Smith & Nephew Incorporated (Smith & Nephew PLC)
• Original Assignee: Smith & Nephew Incorporated (Smith & Nephew PLC)
• Inventors: Miller, Steve, Hunter, Gordon, Schryver, Jeffrey E.
• Application Number:
  US10/323,039
• Publication Number:
  US 20040122524A1
• Time in Patent Office: Days
• US Class Current: 623/22.18
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2/32 for the hip
• CPC Class Codes: A61F 2/36 Femoral heads ; Femoral endoprostheses
• CPC Class Codes: A61F 2/367 Proximal or metaphyseal parts of shafts trochanteric devices connected to said proximal parts A61F2/30739
• CPC Class Codes: A61F 2/3676 Distal or diaphyseal parts of shafts
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/4081 Glenoid components, e.g. cups
• CPC Class Codes: A61F 2002/30322 differing in surface structures
• CPC Class Codes: A61F 2002/3082 Grooves
• CPC Class Codes: A61F 2002/30922 Hardened surfaces
• CPC Class Codes: A61F 2002/30934 Special articulating surfaces
• CPC Class Codes: A61F 2002/30967 Diffusion bonding
• CPC Class Codes: A61F 2002/3208 Bipolar or multipolar joints, e.g. having a femoral head articulating within an intermediate acetabular shell whilst said shell articulates within the natural acetabular socket or within an artificial outer shell
• CPC Class Codes: A61F 2002/3493 Spherical shell significantly greater than a hemisphere, e.g. extending over more than 200 degrees
• CPC Class Codes: A61F 2002/3611 Heads or epiphyseal parts of femur
• CPC Class Codes: A61F 2002/3625 Necks
• CPC Class Codes: A61F 2002/365 Connections of heads to necks
• CPC Class Codes: A61F 2002/4018 Heads or epiphyseal parts of humerus
• CPC Class Codes: A61F 2250/0026 : differing in surface structures
• CPC Class Codes: A61F 2310/00023 : Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00089 : Zirconium or Zr-based alloys
• CPC Class Codes: A61F 2310/00095 : Niobium or Nb-based alloys
• CPC Class Codes: A61F 2310/00125 : Hafnium or Hf-based alloys
• CPC Class Codes: A61F 2310/00131 : Tantalum or Ta-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: A61F 2310/00898 : Coating made of niobium nitride
• CPC Class Codes: A61F 2310/00904 : Coating made of hafnium nitride
• CPC Class Codes: A61F 2310/0091 : Coating made of tantalum nitride
• CPC Class Codes: A61L 2400/18 : Modification of implant surfaces in order to improve biocompatibility, cell growth, fixation of biomolecules, e.g. plasma treatment
• CPC Class Codes: A61L 2430/24 : for joint reconstruction
• CPC Class Codes: A61L 27/306 : Other specific inorganic materials not covered by A61L27/303 - A61L27/32

Abstract

An orthopedic implant having diffusion-hardened surfaces employed at inner and outer load-bearing surfaces. Preferably, the orthopedic implant is a bipolar hip prosthetic device and system where a coating of oxidized zirconium is formed at the articulating, load-bearing surface of the acetabular component and at the articulating, load-bearing surface of the femoral head. The acetabular component has a polymeric cup, made from a bio-compatible material, such as UHMWPE.

Claims

1. A bipolar hip prosthetic device comprising:

a) an acetabular component, the acetabular having an outer surface and an interior surface, said acetabular component formed of zirconium, hafnium, niobium, tantalum or alloys thereof;

b) a polymeric, bio-compatible material lining the interior surface; and

c) a femoral head component, the femoral head component being rotatably secured in said polymeric, bio-compatible material, said femoral head component formed of zirconium, hafnium, niobium, tantalum or alloys thereof;

d) a first diffusion-hardened coating on at least a part of the outer surface of the femoral head component; and

e) a second diffusion-hardened coating on at least a part of said femoral head component.

2. The bipolar hip prosthetic device of claim 1 wherein said first diffusion-hardened coating is an oxide coating selected from the group consisting of oxidized zirconium, oxidized hafnium, oxidized niobium, oxidized tantalum and combinations thereof.

3. The bipolar hip prosthetic device of claim 1 wherein said first diffusion-hardened coating is a nitride coating selected from the group consisting of nitrided zirconium, nitrided hafnium, nitrided niobium, nitrided tantalum and combinations thereof.

4. The bipolar hip prosthetic device of claim 1 wherein said second diffusion-hardened coating is an oxide coating selected from the group consisting of oxidized zirconium, oxidized hafnium, oxidized niobium, oxidized tantalum and combinations thereof.

5. The bipolar hip prosthetic device of claim 1 wherein said second diffusion-hardened coating is a nitride coating selected from the group consisting of nitrided zirconium, nitrided hafnium, nitrided niobium, nitrided tantalum and combinations thereof.

6. The bipolar hip prosthetic device of claim 1 wherein said acetabular component is formed of zirconium or zirconium alloy and said diffusion-hardened coating comprises blue-black or black oxidized zirconium.

7. The bipolar hip prosthetic device of claim 1 wherein said femoral head component is formed of zirconium or zirconium alloy and said diffusion-hardened coating comprises blue-black or black oxidized zirconium.

8. The prosthetic system of claim 1, wherein the first diffusion-hardened coating is a thin coating of blue-black or black zirconium oxide.

9. The prosthetic system of claim 1, wherein the second diffusion-hardened coating is a thin coating of blue-black or black zirconium oxide.

10. The prosthetic system of claim 1, wherein the polymeric bio-compatible material is UHMWPE.

11. The prosthesis of claim 1, wherein the thickness of the first diffusion-hardened coatng is about the same thickness of the second diffusion-hardened coating.

12. The prosthesis of claim 1, further comprising a third diffusion-hardened coating on at least a part of the inner surface of the acetabular component.

13. The bipolar hip prosthetic device of claim 12 wherein said third diffusion-hardened coating is an oxide coating selected from the group consisting of oxidized zirconium, oxidized hafnium, oxidized niobium, oxidized tantalum and combinations thereof.

14. The bipolar hip prosthetic device of claim 12 wherein said third diffusion-hardened coating is a nitride coating selected from the group consisting of nitrided zirconium, nitrided hafnium, nitrided niobium, nitrided tantalum and combinations thereof.

15. The bipolar hip prosthetic device of claim 12 wherein said third diffusion-hardened coating is formed of zirconium or zirconium alloy and said diffusion-hardened coating comprises blue-black or black oxidized zirconium.

16. The bipolar hip prosthetic device of claim 12, wherein said third diffusion-hardened coating is a thin coating of blue-black or black zirconium oxide.

17. The bipolar hip prosthetic device of claim 1, wherein the femoral head component has a composition consisting essentially of about 74 wt % titanium, about 13 wt % niobium, and about 13 wt % zirconium.

18. The bipolar hip prosthetic device of claim 1, wherein the acetabular component has a composition consisting essentially of about 74 wt % titanium, about 13 wt % niobium, and about 13 wt % zirconium.

19. The bipolar hip prosthetic device of claim 1, wherein the femoral head component is formed of alloy having a composition comprising from about 10 to about 20 wt % niobium or from about 35 to about 50 wt % niobium;

from about 13 to about 20 wt % zirconium; and

the balance titanium.

20. The bipolar hip prosthetic device of claim 1, wherein the acetabular component is formed of alloy having a composition comprising from about 10 to about 20 wt % niobium or from about 35 to about 50 wt % niobium;

from about 13 to about 20 wt % zirconium; and

the balance titanium.

21. The bipolar hip prosthetic device of claim 1, wherein the polymeric material is configured to articulate against the inner surface of the acetabular component.

22. The bipolar hip prosthetic device of claim 21, wherein the inner surface of the acetabular component is highly polished.

43. The prosthetic device of claim 17 wherein the first component is a tibial component of a knee joint prosthesis adapted to cooperate with natural tissue of condyles.

23. A prosthetic device, comprising:

(a) a first component being sized and shaped to engage or cooperate with a cavity of a patient, the first component having a diffusion-hardened coating on at least a part of the outer surface of the first component, the first component formed of zirconium, hafnium, niobium, tantalum or alloys thereof;

(b) a biocompatible, polymeric liner disposed within said first component; and

(c) a second component having a diffusion-hardened coating on at least a part of the outer surface of the second component, the second component being sized and shaped to engage or cooperate with the interior surface of the polymeric liner, the first component having a diffusion-hardened coating on at least a part of the outer surface, the first component formed of zirconium, hafnium, niobium, tantalum or alloys thereof.

24. The prosthetic device of claim 23 wherein said diffusion-hardened coating of the first component is an oxide coating selected from the group consisting of oxidized zirconium, oxidized hafnium, oxidized niobium, oxidized tantalum and combinations thereof.

25. The prosthetic device of claim 23 wherein said diffusion-hardened coating of the first component is a nitride coating selected from the group consisting of nitrided zirconium, nitrided hafnium, nitrided niobium, nitrided tantalum and combinations thereof.

26. The prosthetic device of claim 23 wherein said diffusion-hardened coating of the second component is an oxide coating selected from the group consisting of oxidized zirconium, oxidized hafnium, oxidized niobium, oxidized tantalum and combinations thereof.

27. The prosthetic device of claim 23 wherein said diffusion-hardened coating of the second component is a nitride coating selected from the group consisting of nitrided zirconium, nitrided hafnium, nitrided niobium, nitrided tantalum and combinations thereof.

28. The prosthetic device of claim 23 wherein said first component is formed of zirconium or zirconium alloy and said diffusion-hardened coating comprises blue-black or black oxidized zirconium.

29. The prosthetic device of claim 23 wherein said second component is formed of zirconium or zirconium alloy and said diffusion-hardened coating comprises blue-black or black oxidized zirconium.

30. The prosthetic device of claim 23, wherein the diffusion-hardened coating of the first component is a thin coating of blue-black or black zirconium oxide.

31. The prosthetic device of claim 23, wherein the diffusion-hardened coating of the second component is a thin coating of blue-black or black zirconium oxide.

32. The prosthetic device of claim 23, wherein the polymeric bio-compatible material is UIIMWPE.

33. The prosthetic device of claim 23, wherein the thickness of the diffusion-hardened coating of the first component is about the same thickness of the diffusion-hardened coating of the second component.

34. The prosthetic device of claim 23, further comprising a third diffusion-hardened coating on at least a part of an inner surface of the first component.

35. The prosthetic device of claim 34 wherein said third diffusion-hardened coating is an oxide coating selected from the group consisting of oxidized zirconium, oxidized hafnium, oxidized niobium, oxidized tantalum and combinations thereof.

36. The prosthetic device of claim 34 wherein said third diffusion-hardened coating is a nitride coating selected from the group consisting of nitrided zirconium, nitrided hafnium, nitrided niobium, nitrided tantalum and combinations thereof.

37. The prosthetic device of claim 34 wherein said third component is formed of zirconium or zirconium alloy and said diffusion-hardened coating comprises blue-black or black oxidized zirconium.

38. The prosthetic device of claim 34, wherein said third diffusion-hardened coating is a thin coating of blue-black or black zirconium oxide.

39. The prosthetic device of claim 23 wherein the first component is an acetabular head adapted to cooperate with and slide against cartilage tissue of a pelvis.

40. The prosthetic device of claim 23 wherein the first component is a head of a humeral implant adapted to cooperate with natural body tissue of a glenoid of a patient.

41. The prosthetic device of claim 23 wherein the first component is a glenoid prosthesis adapted to cooperate with natural tissue of a humerus.

42. The prosthetic device of claim 23 wherein the first component is a prosthetic with at least one condyle of a femoral component of a knee joint prosthesis adapted to cooperate against natural tissue of a tibia.