Prosthetic hip joint having a polycrystalline diamond compact articulation surface and a counter bearing surface

• US 6,517,583 B1
• Filed: 01/30/2000
• Issued: 02/11/2003
• Est. Priority Date: 01/30/2000
• Status: Expired due to Term

• Current Assignee: Diamicron, Inc.
• Original Assignee: Diamicron, Inc.
• Inventors: Vail, Michael A., Taylor, Jeffrey K., Pope, Bill J., Dixon, Richard H., Jensen, Kenneth M.
• Primary Examiner(s): Willse, David H.
• Assistant Examiner(s): GHERBI, SUZETTE JAIME J
• Application Number:
  US09/494,277
• Time in Patent Office: 1,108 Days
• Field of Search: 623/22.21, 623/22.4, 623/23-1-, 623/23.36, 623/23.6
• US Class Current: 623/23.6
• CPC Class Codes: A61B 17/86 Pins or screws or threaded wires; nuts therefor A61B17/72 take precedence
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2/3099 for temporo-mandibular [TM, TMJ] joints endoprostheses for mandibular reconstruction A61F2/2803
• CPC Class Codes: A61F 2/32 for the hip
• CPC Class Codes: A61F 2/3609 Femoral heads or necks; Connections of endoprosthetic heads or necks to endoprosthetic femoral shafts A61F2/3601 takes precedence
• CPC Class Codes: A61F 2/3662 Femoral shafts
• CPC Class Codes: A61F 2/367 Proximal or metaphyseal parts of shafts trochanteric devices connected to said proximal parts A61F2/30739
• CPC Class Codes: A61F 2/3676 Distal or diaphyseal parts of shafts
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3804 for elbows
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/3868 with sliding tibial bearing
• CPC Class Codes: A61F 2/3877 Patellae or trochleae
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/40 for shoulders
• CPC Class Codes: A61F 2/4059 Humeral shafts
• CPC Class Codes: A61F 2/4081 Glenoid components, e.g. cups
• CPC Class Codes: A61F 2/4241 for hands, e.g. fingers
• CPC Class Codes: A61F 2/4261 for wrists
• CPC Class Codes: A61F 2/442 : Intervertebral or spinal discs, e.g. resilient non-disc-shaped intervertebral inflatable pockets A61F2/441; non-disc-shaped intervertebral fusion implants A61F2/4455
• CPC Class Codes: A61F 2002/30004 : the prosthesis being made from materials having different values of a given property at different locations within the same prosthesis
• CPC Class Codes: A61F 2002/30084 : Materials having a crystalline structure
• CPC Class Codes: A61F 2002/30149 : pentagonal
• CPC Class Codes: A61F 2002/30301 : saddle-shaped
• CPC Class Codes: A61F 2002/30332 : Conically- or frustoconically-shaped protrusion and recess
• CPC Class Codes: A61F 2002/30339 : Double cones, i.e. connecting element having two conical connections, one at each of its opposite ends
• CPC Class Codes: A61F 2002/30364 : Rotation about the common longitudinal axis
• CPC Class Codes: A61F 2002/30398 : Sliding
• CPC Class Codes: A61F 2002/30405 : made by screwing complementary threads machined on the parts themselves
• CPC Class Codes: A61F 2002/30462 : retained or tied with a rope, string, thread, wire or cable
• CPC Class Codes: A61F 2002/3081 : inclined obliquely with respect to each other
• CPC Class Codes: A61F 2002/30878 : with non-sharp protrusions, for instance contacting the bone for anchoring, e.g. keels, pegs, pins, posts, shanks, stems, struts
• CPC Class Codes: A61F 2002/30892 : parallel
• CPC Class Codes: A61F 2002/30894 : inclined obliquely with respect to each other
• CPC Class Codes: A61F 2002/30922 : Hardened surfaces
• CPC Class Codes: A61F 2002/30934 : Special articulating surfaces
• CPC Class Codes: A61F 2002/30968 : Sintering
• CPC Class Codes: A61F 2002/30973 : Two joined adjacent layers having complementary interlocking protrusions and recesses
• CPC Class Codes: A61F 2002/3241 : having a ring, e.g. for locking the femoral head into the acetabular cup
• CPC Class Codes: A61F 2002/3625 : Necks
• CPC Class Codes: A61F 2002/365 : Connections of heads to necks
• CPC Class Codes: A61F 2002/3652 : Connections of necks to shafts
• CPC Class Codes: A61F 2002/3674 : Connections of proximal parts to distal parts
• CPC Class Codes: A61F 2002/3895 : unicompartimental
• CPC Class Codes: A61F 2002/4051 : Connections of heads directly to shafts
• CPC Class Codes: A61F 2002/4062 : Proximal or metaphyseal parts of shafts
• CPC Class Codes: A61F 2002/4077 : Distal or diaphyseal parts of shafts
• CPC Class Codes: A61F 2220/0025 : Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: A61F 2220/0033 : made by longitudinally pushing a protrusion into a complementary-shaped recess, e.g. held by friction fit
• CPC Class Codes: A61F 2220/0075 : sutured, ligatured or stitched, retained or tied with a rope, string, thread, wire or cable
• CPC Class Codes: A61F 2230/0017 : Angular shapes
• CPC Class Codes: A61F 2230/0095 : Saddle-shaped
• CPC Class Codes: A61F 2250/0014 : having different values of a given property or geometrical feature, e.g. mechanical property or material property, at different locations within the same prosthesis
• 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 2310/00065 : Manganese or Mn-based alloys
• CPC Class Codes: A61F 2310/00095 : Niobium or Nb-based alloys
• CPC Class Codes: A61F 2310/00131 : Tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00149 : Platinum or Pt-based alloys
• CPC Class Codes: A61F 2310/00281 : containing silicon carbide
• CPC Class Codes: A61F 2310/0058 : Coating made of diamond or of diamond-like carbon DLC
• CPC Class Codes: A61L 2430/24 : for joint reconstruction
• CPC Class Codes: A61L 27/08 : Carbon ; Graphite
• CPC Class Codes: A61L 27/303 : Carbon
• CPC Class Codes: B22F 2998/00 : Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 2998/10 : Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/1021 : Removal of binder or filler removal of binder from ceramics C04B35/638
• CPC Class Codes: B22F 3/1216 : Container composition
• CPC Class Codes: B22F 3/14 : simultaneously
• CPC Class Codes: B22F 3/24 : After-treatment of workpieces or articles B22F3/1146 takes precedence

Abstract

Prosthetic joints, components for prosthetic joints, superhard bearing and articulation surfaces, diamond bearing and articulation surfaces, substrate surface topographical features, materials for making joints, bearing and articulation surfaces, and methods for manufacturing and finishing the same, and related information are disclosed, including a prosthetic hip joint having a polycrystalline diamond compact articulation surface and a counter bearing surface.

Claims

1. A prosthetic hip joint comprising:

an acetabular cup including a sintered polycrystalline diamond compact,

a substrate located on said acetabular cup polycrystalline diamond compact, said substrate including a metal,

an acetabular cup diamond table sintered to said acetabular cup substrate on said acetabular cup polycrystalline diamond compact, said acetabular cup diamond table,

a zone between said acetabular cup substrate and said acetabular cup diamond table, said zone exhibiting a gradient of solvent-catalyst metal to diamond content, said gradient being selected from the group consisting of interface gradient, continuous gradient and incremental gradient, said zone being referred to as a gradient transition zone,

chemical bonds located in said compact which tend to secure said diamond table to said substrate, said chemical bonds including diamond-to-diamond bonds, diamond-to-metal bonds, and metal-to-metal bonds,

an acetabular cup load bearing and articulation surface on said polycrystalline diamond compact, said acetabular cup load bearing and articulation surface including polycrystalline diamond, said acetabular cup load bearing and articulation surface being formed to present a shape that is at least partially concave spherical and against which a femoral head may articulate,

a femoral head for articulation against said acetabular cup load bearing and articulation surface, and

a femoral head load bearing and articulation surface, said femoral head load bearing and articulation surface being formed to present a shape that is at least partially convex spherical.

2. A joint as recited in claim 1 wherein said femoral head load bearing and articulation surface includes a counter bearing material.

3. A joint as recited in claim 1 wherein said femoral head load bearing and articulation surface includes a counter bearing material selected from the group consisting of monocrystal diamond, natural diamond, polycrystalline diamond, CVD diamond, PVD diamond, cubic boron nitride, wurzitic boron nitride, ceramic, cobalt-chrome alloy, titanium alloy, nickel, vanadium, tantalum, hafnium, molybdenum, cemented tungsten carbide, niobium, zirconia ceramic, alumina ceramic;

polymers, UHMWPE, PEEK, cross-linked polymers and sapphire.

4. A joint as recited in claim 1 wherein said femoral head load bearing and articulation surface includes a counter bearing material that is softer than said acetabular cup load bearing and articulation surface.

5. A joint as recited in claim 1 wherein said femoral head load bearing and articulation surface includes a counter bearing material that includes a metal.

6. A joint as recited in claim 1 further comprising:

a stem for placement into a femur,

a body connecting to said stem,

a neck having a proximal end and a distal end, said neck proximal end connecting to said body and said neck distal end connecting to said femoral head.

7. A joint as recited in claim 6 wherein said femoral head, neck, body and stem are a unitary component.

8. A joint as recited in claim 1 further comprising an acetabular cup shell configured to receive and attach to said acetabular cup.

9. A joint as recited in claim 8 further comprising mechanical fasteners for fastening said acetabular cup shell to a hip bone.

10. A joint as recited in claim 1 further comprising a mechanical grip between said acetabular cup diamond table and said acetabular cup substrate which tends to secure said diamond table to said substrate.

11. A joint as recited in claim 1 further comprising interstitial spaces in said acetabular cup diamond table and veins of solvent-catalyst metal located in said acetabular cup diamond table interstitial spaces.

12. A joint as recited in claim 1 further comprising a residual stress field in said acetabular cup polycrystalline diamond compact that tends to enhance the strength of said acetabular cup polycrystalline diamond compact.

13. A joint as recited in claim 1 wherein diamond in said acetabular cup polycrystalline diamond compact has a coefficient of thermal expansion CTE_Cd, and wherein said substrate in said acetabular cup polycrystalline diamond compact has a coefficient of thermal expansion CTE_sub, and wherein CTE_Cd is not equal to CTE_sub, wherein said diamond in said acetabular cup polycrystalline diamond compact has a modulus M_Cd, and wherein said substrate in said acetabular cup polycrystalline diamond compact has a modulus M_sub, and wherein M_Cd is not equal to M_sub.

14. A joint as recited in claim 1 further comprising a crystalline diamond structure in said acetabular cup polycrystalline diamond compact.

15. A joint as recited in claim 1 further comprising a solvent-catalyst metal present in said acetabular cup polycrystalline diamond compact substrate.

16. A joint as recited in claim 1 further comprising a solvent-catalyst metal present in said acetabular cup polycrystalline diamond compact diamond table.

17. A joint as recited in claim 1 wherein said acetabular cup polycrystalline diamond compact load bearing and articulation surface is polished to a smooth, low-friction finish.

18. A joint as recited in claim 1 wherein said acetabular cup polycrystalline diamond compact load bearing and articulation surface is burnished.

19. A joint as recited in claim 1 wherein said acetabular cup shell includes a bone mating surface on at least a portion of its exterior, said bone mating surface including surface features which enhance frictional engagement with a hip bone.

20. A joint as recited in claim 1 wherein said acetabular cup shell includes a bone mating surface on at least a portion of its exterior, said bone mating surface including a surface coating which encourages bone growth against said coating.

21. A prosthetic hip joint comprising:

a femoral head including a sintered polycrystalline diamond compact,

a substrate located on said femoral head polycrystalline diamond compact, said substrate including a metal,

a femoral head diamond table sintered to said femoral head substrate on said femoral head polycrystalline diamond compact, said femoral head cup diamond table,

a gradient transition zone between said femoral head substrate and said femoral head cup diamond table in said femoral head cup polycrystalline diamond compact, said femoral head gradient transition zone having a substrate side and a diamond table side, said femoral head gradient transition zone having both substrate metal and diamond therein, and said femoral head gradient transition zone exhibiting a transition of ratios of percentage content of substrate metal to diamond from one side of said gradient transition zone to another such that at a first point in said femoral head gradient transition zone near said substrate side, the ratio of percentage content of substrate metal to diamond is greater than it is at a second point in said femoral head cup gradient transition zone closer to said diamond side than said first point,

chemical bonds between said femoral head diamond table and said femoral head substrate which tend to secure said diamond table to said substrate,

a femoral head load bearing and articulation surface on said polycrystalline diamond compact, said femoral head load bearing and articulation surface including polycrystalline diamond, said femoral head load bearing and articulation surface being formed to present a shape that is at least partially concave spherical and against which a femoral head may articulate,

an acetabular cup for accommodating articulation of said femoral head, and

an acetabular cup load bearing and articulation surface, said acetabular cup load bearing and articulation surface being formed to present a shape that is at least partially concave spherical.

22. A joint as recited in claim 21 wherein said acetabular cup load bearing and articulation surface includes a counter bearing material.

23. A joint as recited in claim 21 wherein said acetabular cup load bearing and articulation surface includes a counter bearing material selected from the group consisting of monocrystal diamond, natural diamond, polycrystalline diamond, CVD diamond, PVD diamond, cubic boron nitride, wurzitic boron nitride, ceramic, cobalt-chrome alloy, titanium alloy, nickel, vanadium, tantalum, hafnium, molybdenum, cemented tungsten carbide, niobium, zirconia ceramic, alumina ceramic, polymers, UHMWPE, PEEK, cross-linked polymers and sapphire.

24. A joint as recited in claim 21 wherein said femoral head load bearing and articulation surface includes a counter bearing material that is softer than said femoral head load bearing and articulation surface.

25. A joint as recited in claim 21 wherein said femoral head load bearing and articulation surface includes a counter bearing material that includes a metal.

26. A joint as recited in claim 21 further comprising:

a stem for placement into a femur,

a body connecting to said stem,

a neck having a proximal end and a distal end, said neck proximal end connecting to said body and said neck distal end connecting to said femoral head.

27. A joint as recited in claim 26 wherein said femoral head, neck, body and stem are a unitary component.

28. A joint as recited in claim 26 wherein said femoral head, neck, body and stem are modular components assembleable with each other.

29. A joint as recited in claim 21 further comprising an acetabular cup shell configured to receive and attach to said acetabular cup.

30. A joint as recited in claim 29 further comprising at least one mechanical fastener for fastening said acetabular cup shell to a hip bone.

31. A joint as recited in claim 21 further comprising a mechanical grip between said femoral bead diamond table and said femoral head substrate which tends to secure said diamond table to said substrate.

32. A joint as recited in claim 21 further comprising interstitial spaces in said femoral head diamond table and veins of solvent-catalyst metal located in said femoral head diamond table interstitial spaces.

33. A joint as recited in claim 21 further comprising a residual stress field in said femoral head polycrystalline diamond compact that tends to enhance the strength of said femoral head polycrystalline diamond compact.

34. A joint as recited in claim 21 wherein diamond in said femoral head polycrystalline diamond compact has a coefficient of thermal expansion CTE_Cd, and wherein said substrate in said femoral head polycrystalline diamond compact has a coefficient of thermal expansion CTE_sub, and wherein CTE_Cd is not equal to CTE_sub, wherein said diamond in said femoral head cup polycrystalline diamond compact has a modulus M_Cd, and wherein said substrate in said femoral head polycrystalline diamond compact has a modulus M_sub, and wherein M_Cd, is not equal to M_sub.

35. A joint as recited in claim 21 further comprising a crystalline diamond structure in said femoral head polycrystalline diamond compact.

36. A joint as recited in claim 21 further comprising a solvent-catalyst metal present in said femoral head polycrystalline diamond compact substrate.

37. A joint as recited in claim 21 wherein said femoral head polycrystalline diamond compact load bearing and articulation surface is polished to a smooth, low-friction finish.

38. A joint as recited in claim 21 wherein said femoral head polycrystalline diamond compact load bearing and articulation surface is burnished.

39. A prosthetic hip joint comprising:

an acetabular cup, and

a femoral head;

wherein at least one of said acetabular cup and said femoral head is at least partially formed by a polycrystalline diamond compact; and

wherein the other of said acetabular cup and femoral head serves as a counter bearing surface for said polycrystalline diamond.

40. A prosthetic hip joint as recited in claim 39 wherein said diamond compact comprises:

a substrate that includes a solvent-catalyst metal,

a diamond layer sintered to said substrate,

a zone between said substrate and said diamond layer that has a composition gradient of decreasing solvent-catalyst metal content across said zone,

chemical bonds in said zone, said chemical bonds including diamond-to-diamond bonds in said diamond table, diamond-to-metal bonds in said gradient transition zone, and metal-to-metal bonds in said solvent-catalyst metal,

a mechanical grip between said diamond layer and said substrate which tends to secure said diamond layer to said substrate,

interstitial spaces in said diamond layer,

solvent-catalyst metal present in said interstitial spaces, and

a non-planar load bearing and articulation surface formed by said diamond layer.

41. A joint as recited in claim 40 wherein sintered diamond in said diamond layer has a coefficient of thermal expansion CTE_Cd, and wherein said substrate has a coefficient of thermal expansion CTE_sub, and wherein CTE_Cd is not equal to CTE_sub.

42. A joint as recited in claim 40 wherein said sintered diamond in said diamond layer has a modulus M_Cd and wherein said substrate has a modulus M_sub, and wherein M_Cd, is not equal to M_sub.

43. A joint as recited in claim 41 further comprising a residual stress field that tends to enhance the strength of attachment of said diamond layer to said substrate.

44. A joint as recited in claim 43 wherein said residual stress field is caused by dilitation of said substrate.

45. A joint as recited in claim 40 further comprising substrate surface topographical features on said substrate.

46. A joint as recited in claim 41 wherein said substrate includes a metal alloy with at least one component of said metal alloy being selected from the group consisting of titanium, aluminum, vanadium, molybdenum, hafniun, nitinol, cobalt, chrome, molybdenum, tungsten, cemented tungsten carbide, cemented chrome carbide, fused silicon carbide, nickel, tantalum, and stainless steel.

47. A joint as recited in claim 40 wherein said diamond layer includes diamond feedstock that has diamond particles that have a dimension in the range of less than about 1 nanometer to more than about 100 microns.

48. A joint as recited in claim 40 wherein said diamond layer includes diamond particles having a size of less than about 100 nanometers.

49. A joint as recited in claim 40 wherein said diamond load bearing and articulation surfaces is a continuous diamond surface.

50. A joint as recited in claim 40 wherein said diamond load bearing and articulation surface is a discontinuous diamond surface.

51. A joint as recited in claim 40 wherein said diamond load bearing and articulation surface is a segmented diamond surface.

52. A joint as recited in claim 40 wherein a lip is present on said substrate in order to interlock said diamond layer to said substrate.

53. A joint as recited in claim 40 further comprising CoCr solvent-catalyst metal in interstitial spaces in said diamond layer.

54. A joint as recited in claim 40 further comprising a continuous gradient in said diamond layer.

55. A joint as recited in claim 40 further comprising an incremental gradient in said diamond layer.

56. A joint as recited in claim 55 wherein said incremental gradient includes a plurality of strata in said diamond layer, a first of said strata having characteristics which differ from those of a second strata.

57. A joint as recited in claim 56 wherein said differing characteristics of said strata are selected from the group consisting of diamond particle size, diamond particle distribution, and solvent-catalyst metal content.

58. A component as recited in claim 50 further comprising an interface gradient.

59. A component as recited in claim 50 wherein said diamond layer has a thickness of from less than about 1 micron to more than about 3000 microns.

60. A prosthetic hip joint comprising

an acetabular cup, and

a femoral head;

wherein at least one of said acetabular cup and said femoral head is a polycrystalline diamond compact including both a substrate and a diamond table attached to said substrate, said compact including;

a substrate,

a diamond table sintered to said substrate,

interstitial spaces located in said diamond table,

solvent-catalyst metal located in said interstitial spaces,

a zone that includes both sintered diamond and substrate, said zone having a composition gradient of solvent-catalyst metal content to diamond content, said gradient being selected from the group consisting of interface gradient, continuous gradient and incremental gradient,

chemical bonds in the component, said chemical bonds including diamond-to-diamond bonds in said diamond table, diamond-to-metal bonds in said zone, and metal-to-metal bonds in said solvent-catalyst metal,

a mechanical grip between said diamond table and said substrate which tends to secure said diamond table to said substrate, and

a non-planar load bearing and articulation surface formed by said diamond table; and

wherein the other of said acetabular cup and said femoral head has a load bearing and articulation surface formed from a counter bearing material.

61. A joint as recited in claim 60 wherein said counter bearing material is selected from the group consisting of monocrystal diamond, natural diamond, polycrystalline diamond, CVD diamond, PVD diamond, cubic boron nitride, wurzitic boron nitride, ceramic, cobalt-chrome alloy, titanium alloy, nickel, vanadium, tantalum, hafnium, molybdenum, cemented tungsten carbide, niobium, zirconia ceramic, alumina ceramic, polymers, UHMWPE, PEEK, cross-linked polymers and sapphire.

62. A joint as recited in claim 60 wherein said counter bearing material that is softer than diamond.

63. A joint as recited in claim 60 wherein said counter bearing material includes a metal.

64. A joint as recited in claim 60 further comprising a lip of substrate material which serves to secure said diamond table to said substrate.

65. A joint as recited in claim 60 wherein said substrate includes a metal alloy with at least one component of said metal alloy being selected from the group consisting of titanium, aluminum, vanadium, molybdenum, hafnium, nitinol, cobalt, chrome, molybdenum, tungsten, cemented tungsten carbide, cemented chrome carbide, fused silicon carbide, nickel, tantalum, and stainless steel.

66. A joint as recited in claim 60 wherein said diamond table has a thickness of from less than about 1 micron to more than about 3000 microns.

67. A joint as recited in claim 60 wherein said diamond table is made using diamond feedstock having particles that have a dimension in the range of less than about 1 nanometer to more than about 100 microns.

68. A joint as recited in claim 60 wherein said diamond table is made using said diamond feedstock having particles that have a dimension in the range of less than about 0.1 micron to more than about 10 microns.

69. A joint as recited in claim 60 wherein said diamond table is made using said diamond feedstock having particles that have a dimension in the range of less than about 0.5 micron to more than about 2 microns.

70. A joint as recited in claim 60 wherein said diamond load bearing and articulation surface is a continuous diamond surface.

71. A joint as recited in claim 60 wherein said diamond load bearing and articulation surface is a discontinuous diamond surface.

72. A joint as recited in claim 60 wherein said diamond load bearing and articulation surface is a segmented diamond surface.

73. A joint as recited in claim 60 further comprising substrate surface topographial features on said substrates.

74. A joint as recited in claim 60 wherein said substrate and said diamond table are dovetailed together to form a strong mechanical interlock between said substrate and said diamond table.

75. A joint as recited in claim 60 wherein said diamond table includes sp3 carbon bonds.

76. A joint as recited in claim 60 wherein said gradient includes a plurality of strata in said diamond table, a first of said strata having, characteristics which differ from those of a second strata.

77. A joint as recited in claim 76 wherein said differing characteristics are selected from the group consisting of diamond particle size, diamond particle distribution, and solvent-catalyst metal content.