Acetabular Shell System and Method for Making

• US 20100136214A1
• Filed: 02/01/2010
• Published: 06/03/2010
• Est. Priority Date: 03/03/2005
• Status: Abandoned Application

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Kumar, Mukesh
• Application Number:
  US12/697,847
• Publication Number:
  US 20100136214A1
• Time in Patent Office: Days
• US Class Current: 427/2.270
• CPC Class Codes: A61L 27/306 Other specific inorganic materials not covered by A61L27/303 - A61L27/32

Abstract

A method for forming an acetabular shell includes providing a working surface such as a mandrel, and spraying the working surface with a first layer of material having a first composition such as aluminum oxide. After a suitable thickness is generated, the spray composition is gradually changed to other compositions having desired particle sizes and distribution. In one example, the composition is changed to a mixture of aluminum oxide and titanium oxide and/or titanium. As thickness builds up, the relative amount of aluminum oxide is decreased such that the composition is all titanium and titanium oxide. After a desired thickness is generated, the acetabular shell is extracted off the mandrel.

Claims

1. A method of making an implant for use in replacing a portion of a patient'"'"'s joint, the method comprising:

providing a first die defining a concave cavity having a textured die surface;

providing a second die defining a convex extension surface, the first and second die collectively forming a die cavity;

coating the textured die surface with powdered metal;

injecting a slurry of material into the die cavity;

casting the slurry of material thereby forming a ceramic shell;

removing the ceramic shell from the die cavity, the ceramic shell having a first surface and a second surface, the second surface being formed of metal from the powdered metal;

driving off excess fluid slurry by converting the ceramic shell to a stable dome in an oven;

locating the stable dome onto a mounting instrument;

plasma spraying a layer of material onto an outer surface of the stable dome that corresponds to the second surface of the ceramic shell; and

sintering the ceramic shell.

2. The method of claim 1, further comprising polishing the second surface of the ceramic shell.

3. The method of claim 1 wherein forming the ceramic shell comprises casting a ceramic shell having a textured outboard surface having a plurality of dimples, the textured outboard surface adapted to accept the sprayed layer of material.

4. The method of claim 3 wherein plasma spraying the layer of material comprises spraying titanium oxide onto the second surface of the ceramic shell.

5. The method of claim 1 wherein the textured die surface includes a plurality of outwardly extending knobs