DUAL MODULUS HIP STEM AND METHOD OF MAKING THE SAME

• US 20150069111A1
• Filed: 11/20/2014
• Published: 03/12/2015
• Est. Priority Date: 06/18/2012
• Status: Active Grant

• Current Assignee: DePuy Synthes Products LLC (Johnson & Johnson)
• Original Assignee: DePuy Synthes Products LLC (Johnson & Johnson)
• Inventors: Armacost, John M., Keefer, Ryan C., McAnelly, Jeffrey A.
• Granted Patent: US 11,020,232 B2
• Time in Patent Office: Days
• US Class Current: 228/101
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2/3607 including proximal or total replacement of the femur
• CPC Class Codes: A61F 2/3662 Femoral shafts
• CPC Class Codes: A61F 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/30014 differing in elasticity, stiffness or compressibility
• CPC Class Codes: A61F 2002/3011 Cross-sections or two-dimensional shapes
• CPC Class Codes: A61F 2002/30405 made by screwing complementary threads machined on the parts themselves
• CPC Class Codes: A61F 2002/30919 Sleeves
• 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 2002/30971 Laminates, i.e. layered products
• CPC Class Codes: A61F 2002/3631 with an integral complete or partial peripheral collar or bearing shoulder at its base
• CPC Class Codes: A61F 2002/365 Connections of heads to necks
• CPC Class Codes: A61F 2002/3654 Connections of heads directly to shafts
• CPC Class Codes: A61F 2002/3678 Geometrical features
• 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 2310/00407 Coating made of titanium or of Ti-based alloys
• CPC Class Codes: A61F 2310/00413 Coating made of cobalt or of Co-based alloys
• CPC Class Codes: B23K 1/0008 specially adapted for particular articles or work
• CPC Class Codes: B23K 20/002 : specially adapted for particular articles or work B23K20/129 takes precedence
• CPC Class Codes: B23K 20/02 : by means of a press ; Diffusion bonding B23K20/001, B23K20/04 take precedence
• CPC Class Codes: Y10T 29/49826 : Assembling or joining

Abstract

An orthopaedic prosthesis for use in a hip replacement surgery. The orthopaedic prosthesis includes a metallic foam shell and a metallic core. The metallic core includes a neck configured to receive a femoral head component and a stem extending through the metallic foam shell.

Claims

1. A method of manufacturing an orthopaedic prosthesis for a patient, comprising:

producing a shell from a metallic foam material having a first elastic modulus,

producing a stem core from a metallic material having a second elastic modulus greater than the first elastic modulus, the stem core including a neck configured to receive a femoral head component, and

securing the shell to the stem core such that (i) the shell is positioned over a proximal segment of the stem core, and (ii) a cover layer of the shell extends along a lateral surface of a distal segment of the stem core.

2. The method of claim 1, wherein producing the shell includes forming a sheath over the proximal segment of the stem core such that the proximal segment of the stem core is encased therein.

3. The method of claim 2, wherein forming the sheath includes setting a medial thickness of the shell to between one millimeter and 1.5 millimeters at a distal end of the sheath.

4. The method of claim 1, wherein securing the shell to the core includes sintering the shell to the core.

5. The method of claim 1, wherein producing the shell from the metallic foam material includes:

compressing the metallic foam material around the stem core, and

machining the metallic foam material to form the shell.

6. The method of claim 1, wherein producing the shell from the metallic foam material includes:

compressing the metallic foam material to form an outer geometry of the shell, and

machining a channel in the metallic foam material sized to receive the stem core.