Cementless Tibial Tray

• US 20090084491A1
• Filed: 09/24/2008
• Published: 04/02/2009
• Est. Priority Date: 09/25/2007
• Status: Abandoned Application

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Metzger, Robert, Uthgenannt, Brian A., Hershberger, Troy W.
• Application Number:
  US12/236,992
• Publication Number:
  US 20090084491A1
• Time in Patent Office: Days
• US Class Current: 156/153
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2002/3092 having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30968 Sintering
• CPC Class Codes: A61F 2002/3097 using laser
• CPC Class Codes: A61F 2002/30971 Laminates, i.e. layered products
• 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 2310/00059 Chromium or Cr-based alloys
• CPC Class Codes: A61F 2310/00131 Tantalum or Ta-based alloys
• CPC Class Codes: A61L 27/06 Titanium or titanium alloys
• CPC Class Codes: A61L 27/30 Inorganic materials
• CPC Class Codes: A61L 27/34 Macromolecular materials
• CPC Class Codes: A61L 27/56 Porous materials, e.g. foams or sponges
• CPC Class Codes: C08L 71/12 Polyphenylene oxides

Abstract

The present teachings provide a tibial tray and a method for making the same. According to one example, a substrate having a superior surface can be formed. Porous metal material can be attached onto the superior surface of the substrate. Selected areas of the substrate can be removed to form first features of the tibial tray. Selected areas of the polymer portion can be removed to form second features of the tibial tray.

Claims

1. A method of making a tibial tray, the method comprising:

forming a substrate having a superior surface;

attaching porous metal material onto the superior surface;

attaching a polymer portion onto the porous metal material;

removing selected areas of the substrate to form first features of the tibial tray; and

removing selected areas of the polymer portion to form second features of the tibial tray.

2. The method of claim 1 wherein attaching the porous metal material comprises sintering the porous metal material onto the superior surface of the substrate.

3. The method of claim 1 wherein attaching the polymer portion comprises molding the polymer portion onto the porous metal material.

4. The method of claim 1 wherein removing selected areas of the substrate comprises forming portions of a tibial stem.

5. The method of claim 1 wherein removing selected areas of the substrate comprises exposing at least portions of the porous metal material.

6. The method of claim 1 wherein removing selected areas of the polymer portion comprises forming a superior surface of the tibial tray including attachment features adapted for selectively securing a bearing.

7. The method of claim 1, further comprising attaching a foil barrier intermediate the porous metal material and the polymer portion.

8. A method of making a tibial tray, the method comprising:

forming a substrate having a superior surface;

attaching porous metal material to the superior surface;

forming a non-porous layer on the porous metal material;

attaching a polymer portion to the non-porous layer; and

removing selected areas of the substrate to form first features of the tibial tray.

9. The method of claim 8 wherein attaching the porous metal material comprises sintering the porous metal material onto the superior surface of the substrate.

10. The method of claim 8 wherein attaching the polymer portion comprises heating at least one of the polymer portion and the porous metal material, placing the polymer portion onto the porous metal material, and cooling at least one of the polymer portion and the porous metal material.

11. The method of claim 8 wherein removing selected areas of the substrate comprises forming portions of a tibial stem.

12. The method of claim 8 wherein removing selected areas of the substrate comprises exposing at least portions of the porous metal material.

13. The method of claim 8 wherein forming the non-porous layer includes attaching a foil barrier onto the porous metal material.

14. A method of making a tibial tray, the method comprising:

forming a titanium substrate having a first superior surface;

attaching porous metal material to the first superior surface by applying at least one of heat and pressure to at least one of the substrate and porous metal material, the porous metal material having a second superior surface;

molding polyetheretherketone (PEEK) onto the second superior surface;

removing selected areas of the substrate to form a stem; and

removing selected areas of the PEEK to form attachment features that are configured to selectively secure a bearing and to expose at least one portion of the porous metal material.

15. The method of claim 14 wherein attaching the porous metal material comprises sintering the porous metal material to the superior surface of the substrate.

16. The method of claim 14 wherein attaching the porous metal material comprises welding the porous metal material to the superior surface of the substrate.

17. The method of claim 14 wherein the porous metal material is titanium.

18. The method of claim 17 wherein attaching the porous metal material comprises diffusion bonding the substrate to the porous metal material.

19. The method of claim 17 wherein attaching the porous metal material comprises metallurgical bonding the substrate to the porous metal material.

20. The method of claim 14, further comprising attaching a bearing to the PEEK.