INTEGRATED PROSTHETIC ELEMENT
First Claim
1. Integrated prosthetic element usable for bone implant operations as a femoral, shoulder or knee prosthesis, or as a bone filler or replacement, insert or shell, comprising at least a metal support and an insert made of plastic material coupled with at least a first surface of said metal support so as to define a wear surface, or insert, of adjustable thickness, open towards a mobile part of a prosthesis, said metal support comprising, on a side opposite said first surface, a second surface intended to be coupled with the bone part on which the prosthesis or bone replacement is installed, wherein said first surface comprises a solidarization layer, having cavities or holes which extend internally said first surface and are distributed in a substantially uniform manner and suitable for anchorage and solidarization of the plastic material that makes up the insert, while said second surface comprises a porous layer suitable to optimize the bone anchorage, wherein said first surface and said second surface are separated by a compact layer that stops the liquid or semi-liquid plastic material in the step of forming the plastic insert, and wherein the cavities or holes of the first surface have bigger shapes and sizes than, and in any case different from, the pores of the second surface, and wherein the metal support, with the solidarization layer, the compact layer and the porous layer are all obtained using either the Electron Beam Melting Technique (EBM), or a technique using a high power laser ray, from a powder material based on pure titanium, or an alloy thereof, or cobalt alloys, tantalum alloys or other suitable biocompatible alloy.
1 Assignment
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Accused Products
Abstract
Integrated prosthetic element usable for bone implant operations or as a bone filler or replacement, comprising at least a metal support and an insert made of plastic material coupled with at least a first surface of said metal support so as to define a wear surface, or insert, of adjustable thickness. The metal support comprises, on the side opposite said first surface, a second surface intended to be coupled with the bone part on which the prosthesis or bone replacement is installed. The first surface comprises a layer having cavities or holes distributed in a substantially uniform manner and suitable for anchorage and solidarization of the plastic material that makes up the insert, while said second surface comprises a porous layer suitable to optimize the bone anchorage. The first surface and the second surface are separated by a compact layer that stops the plastic material in the step of forming the plastic insert. The cavities or holes of the first surface have bigger shapes and sizes than, and in any case different from, the pores of the second surface.
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Citations
9 Claims
- 1. Integrated prosthetic element usable for bone implant operations as a femoral, shoulder or knee prosthesis, or as a bone filler or replacement, insert or shell, comprising at least a metal support and an insert made of plastic material coupled with at least a first surface of said metal support so as to define a wear surface, or insert, of adjustable thickness, open towards a mobile part of a prosthesis, said metal support comprising, on a side opposite said first surface, a second surface intended to be coupled with the bone part on which the prosthesis or bone replacement is installed, wherein said first surface comprises a solidarization layer, having cavities or holes which extend internally said first surface and are distributed in a substantially uniform manner and suitable for anchorage and solidarization of the plastic material that makes up the insert, while said second surface comprises a porous layer suitable to optimize the bone anchorage, wherein said first surface and said second surface are separated by a compact layer that stops the liquid or semi-liquid plastic material in the step of forming the plastic insert, and wherein the cavities or holes of the first surface have bigger shapes and sizes than, and in any case different from, the pores of the second surface, and wherein the metal support, with the solidarization layer, the compact layer and the porous layer are all obtained using either the Electron Beam Melting Technique (EBM), or a technique using a high power laser ray, from a powder material based on pure titanium, or an alloy thereof, or cobalt alloys, tantalum alloys or other suitable biocompatible alloy.
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8. Method to make an integrated prosthetic element usable for bone implant operations as a femoral, shoulder or knee prosthesis, or as a bone filler or replacement, insert or shell, comprising at least a metal support and an insert made of plastic material coupled with at least a first surface of said metal support so as to define a wear surface, or insert, of adjustable thickness, open towards a mobile part of a prothesis, said metal support comprising, on the side opposite said first surface, a second surface intended to be coupled with the bone part on which the prosthesis or bone replacement is installed, the method comprising making the metal support so as to define at least an intermediate compact layer between said first and said second surface, wherein cavities or holes are made on said first surface which extend internally said first surface so as to define a solidarization layer, whereas on said second surface there is a surface porosity, and feeding, casting or injecting plastic material in a liquid or semi-liquid state, which penetrates into said cavities or holes of the solidarization layer until the compact layer is reached, wherein said cavities or holes extend inside and create at least undercuts, or are open cavities intercommunicating and connected with each other, and wherein said metal support and the relative first and second surface are made in a single process using either an EBM (Electron Beam Melting) technique or a technique using a high power laser ray, on a powder material selected between pure titanium, or an alloy thereof, or cobalt alloys, tantalum alloys or other suitable biocompatible alloy.
Specification