Prosthetic device

• US 20070255412A1
• Filed: 04/13/2007
• Published: 11/01/2007
• Est. Priority Date: 04/18/2006
• Status: Abandoned Application

• Current Assignee: University of Florida Research Foundation, Incorporated (State University System of Florida), MAKO Surgical Corporation (Stryker Corporation)
• Original Assignee: University of Florida Research Foundation, Incorporated (State University System of Florida)
• Inventors: Abovitz, Rony, Hajaj, Binyamin, Sawyer, Wallace
• Application Number:
  US11/786,929
• Publication Number:
  US 20070255412A1
• Time in Patent Office: Days
• US Class Current: 623/17.110
• CPC Class Codes: A61F 2/30723 Plugs or restrictors for sealing a cement-receiving space tools for inserting plugs A61F2/4614; sealing collars for use during cementing A61B17/8808
• CPC Class Codes: A61F 2/30756 Cartilage endoprostheses A61F2/3603 takes precedence
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/30771 applied in original prostheses, e.g. holes or grooves
• CPC Class Codes: A61F 2/30907 Nets or sleeves applied to surface of prostheses or in cement
• CPC Class Codes: A61F 2/30965 Reinforcing the prosthesis by embedding particles or fibres during moulding or dipping
• CPC Class Codes: A61F 2/32 for the hip
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2002/30769 madreporic
• CPC Class Codes: A61F 2002/30915 made of a stack of bonded perforated sheets, grids or wire meshes
• CPC Class Codes: A61F 2002/3092 having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30971 Laminates, i.e. layered products
• CPC Class Codes: A61F 2002/3895 unicompartimental
• CPC Class Codes: A61F 2240/001 Designing or manufacturing processes
• CPC Class Codes: A61F 2310/00017 Iron- or Fe-based alloys, e.g. stainless steel
• CPC Class Codes: A61F 2310/00023 Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00029 Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• CPC Class Codes: A61F 2310/00131 Tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00161 : Carbon; Graphite
• CPC Class Codes: A61F 2310/00179 : Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00203 : containing alumina or aluminium oxide
• CPC Class Codes: A61F 2310/00239 : containing zirconia or zirconium oxide ZrO2
• CPC Class Codes: A61F 2310/00796 : Coating or prosthesis-covering structure made of a phosphorus-containing compound, e.g. hydroxy(l)apatite

Abstract

A prosthetic device includes a first component and a second component. The first component of the prosthetic device includes a polymer composite configured as an articular surface and having a wear rate of less than approximately 10⁻⁷ mm³/Nm. The polymer composite includes a first polymer and a second polymer. The first polymer comprises at least 10 weight percent of the polymer composite. The second component of the prosthetic device is configured to be implanted on a bone and includes a region of porosity that is customized for bone in-growth in a specific joint of a patient.

Claims

1. A prosthetic device comprising:

a first component including a polymer composite configured as an articular surface, the polymer composite including a first polymer and a second polymer,

the first polymer comprising at least 10 weight percent of the polymer composite and a wear rate of the polymer composite being less than approximately 10<sup>−

7</sup> mm³/Nm, and a second component configured to be implanted on a bone, the second component including a region of porosity that is customized for bone in-growth in a specific joint of a patient.

2. The prosthetic device of claim 1, wherein the porosity is configured for bone in-growth of a predetermined type of bone.

3. The prosthetic device of claim 1, wherein the first polymer is configured to promote articulation.

4. The prosthetic device of claim 1, wherein the first polymer is configured to reduce at least one of friction and wear during articulation.

5. The prosthetic device of claim 1, wherein the second polymer is configured to promote bone in-growth.

6. The prosthetic device of claim 1, where the first polymer is selected from the group consisting of PTFE, ultra-high molecular weight polyethylene, and nylon.

7. The prosthetic device of claim 1, wherein the second polymer is selected from the group consisting of PEEK, polyaryletherketone, polyimide, nylon, polycarbonate, acrylonitrile, ABS, and ultra-high molecular weight polyethylene.

8. The prosthetic device of claim 1, wherein the second polymer comprises between about 10 weight percent and about 90 weight percent of the polymer composite.

9. The prosthetic device of claim 8, wherein the second polymer comprises about 50 weight percent or less of the polymer composite.

10. The prosthetic device of claim 1, wherein a modulus of elasticity of at least a portion of the first component is similar to a modulus of elasticity of cartilage.

11. The prosthetic device of claim 1, wherein a modulus of elasticity of at least a portion of the second component is similar to a modulus of elasticity of at least one of cancellous bone and cortical bone.

12. The prosthetic device of claim 1, wherein the region of porosity of the second component has a microstructure similar to a microstructure of at least one of cancellous bone and cortical bone.

13. The prosthetic device of claim 1, wherein the region of porosity of the second component includes a porous substrate.

14. The prosthetic device of claim 13, wherein the porous substrate includes a cellular structure that is substantially random.

15. The prosthetic device of claim 13, wherein the porous substrate includes a cellular structure that is substantially predetermined.

16. The prosthetic device of claim 13, wherein the porous substrate includes a cellular structure that is substantially predetermined and has a substantially non-homogenous structure.

17. The prosthetic device of claim 13, wherein the porous substrate comprises at least one of a metal, a polymer, a ceramic, and a carbon.

18. The prosthetic device of claim 17, wherein the metal is selected from the group consisting of tantalum, titanium, cobalt chrome, stainless steel, and zirconium.

19. The prosthetic device of claim 13, wherein the porous substrate includes a coating.

20. The prosthetic device of claim 19, wherein the coating includes at least one of a metal, a polymer, a ceramic, and a material configured to promote bone in-growth.

21. The prosthetic device of claim 20, wherein the metal is selected from the group consisting of tantalum, titanium, cobalt chrome, stainless steel, and zirconium.

22. The prosthetic device of claim 1, wherein the region of porosity of the second component comprises a plurality of layers.

23. The prosthetic device of claim 22, wherein each layer includes a plurality of cellular voids.

24. The prosthetic device of claim 23, wherein the layers are configured so that the cellular voids are oriented substantially randomly.

25. The prosthetic device of claim 23, wherein the layers are configured so that the cellular voids are oriented in a substantially predetermined manner.

26. The prosthetic device of claim 23, wherein the layers are configured so that the cellular voids are oriented in a substantially predetermined manner and have a substantially non-homogenous structure.

27. The prosthetic device of claim 22, wherein the layers are configured to transfer at least a portion of a load from the prosthetic device to the bone in a predetermined manner.

28. The prosthetic device of claim 22, wherein at least one of the layers comprises at least one of a metal, a polymer, and a ceramic.

29. The prosthetic device of claim 22, wherein the layers are joined by at least one of bonding, a mechanical joint, a chemical joint, and an adhesive.

30. The prosthetic device of claim 22, wherein the plurality of layers includes a first layer and a second layer, the second layer including at least one elastic property that is different from an elastic property of the first layer.

31. The prosthetic device of claim 30, wherein first and second layers are arranged to control stress concentration in the bone.

32. The prosthetic device of claim 1, wherein the region of porosity of the second component includes a porosity of between about 60 percent to about 90 percent.

33. The prosthetic device of claim 32, wherein the region of porosity of the second component includes a porosity of between about 75 percent to about 85 percent.

34. The prosthetic device of claim 32, wherein the region of porosity of the second component includes a porosity of approximately 70 percent.

35. The prosthetic device of claim 32, wherein the region of porosity of the second component includes a porosity of approximately 80 percent.

36. The prosthetic device of claim 1, wherein the second component includes at least one of a porous coating and a bioactive coating.

37. The prosthetic device of claim 36, wherein the porous coating is selected from the group consisting of beads, plasma spray, and mesh.

38. The prosthetic device of claim 36, wherein the bioactive coating comprises hydroxyapatite.

39. The prosthetic device of claim 1, wherein at least a portion of the second component includes the polymer composite.

40. The prosthetic device of claim 39, wherein at least a portion of the polymer composite in the second component is coated with a bioactive coating.

41. The prosthetic device of claim 1, wherein the second component includes a textured surface.

42. The prosthetic device of claim 41, wherein the textured surface is coated with a bioactive coating.

43. The prosthetic device of claim 1, wherein the first component is configured to be attached to a plurality of biological cells.

44. The prosthetic device of claim 43, wherein the cells comprise at least one of cartilage cells and stem cells.

45. The prosthetic device of claim 1, wherein the first and second components are configured to be bonded together.

46. The prosthetic device of claim 1, wherein the first and second components are configured to be molded together.

47. The prosthetic device of claim 1, wherein the region of porosity of the second component is configured to limit a depth of penetration of the polymer composite when the first component and the second component are molded together.

48. The prosthetic device of claim 1, wherein the first component is integral with the second component.

49. The prosthetic device of claim 1, wherein the second component includes a first surface configured to interface with the bone and a second surface configured to interface with the first component.

50. The prosthetic device of claim 1, wherein the second component is configured to limit a depth of bone in-growth into the region of porosity.

51. The prosthetic device of claim 1, wherein the prosthetic device is configured as a joint implant.

52. The prosthetic device of claim 51, wherein the joint implant is a total joint implant.

53. The prosthetic device of claim 51, wherein the joint implant is a partial joint implant.

54. The prosthetic device of claim 51, wherein the joint implant is a local defect implant.

55. The prosthetic device of claim 1, further comprising a third component configured to be implanted on a bone, wherein the third component includes a region of porosity that is customized for bone in-growth in the specific joint.

56. The prosthetic device of claim 55, wherein the first component is configured to be disposed between the second component and the third component when the prosthetic device is implanted on a spine of a patient.

57. The prosthetic device of claim 56, wherein a modulus of elasticity of at least a portion of the first component is similar to a modulus of elasticity of an intervertebral disc.

58. The prosthetic device of claim 56, wherein a modulus of elasticity of at least a portion of the second component and/or the third component is similar to a modulus of elasticity of a vertebral body.

59. A prosthetic device for implantation in a patient, comprising:

a bearing surface comprising a polymer composite including a first polymer and a second polymer and having a wear rate that is less than approximately 10<sup>−

7</sup> mm³/Nm, the first polymer being at least 10 weight percent of the polymer composite, and

a fixation portion including a plurality of cavities, the volume percent of the cavities in the fixation portion being determined based on one or more aspects of a specific joint of the patient.

60. The prosthetic device of claim 59, wherein the volume percent is determined based on at least one of bone structure of the specific joint and one or more growth characteristics of the specific joint.

61. A method of making a prosthetic device, comprising:

providing a polymer composite that includes a first polymer and a second polymer, wherein the first polymer comprises at least 10 weight percent of the polymer composite and a wear rate of the polymer composite is less than approximately 10<sup>−

7</sup> mm³/Nm,

providing a porous material, wherein a porosity of the porous material is determined based on characteristics of a bone of a specific joint of a patient,

forming an articular surface from the polymer composite,

forming a fixation component from the porous material, wherein the fixation component is configured to be implanted on the bone, and

connecting the articular surface to the fixation component.

62. The method of claim 61, wherein the step of connecting the articular surface to the fixation component includes connecting the articular surface to a first side of an intermediate component and connecting the fixation component to a second side of the intermediate component.