Prosthetic joint component having at least one sintered polycrystalline diamond compact articulation surface and substrate surface topographical features in said polycrystalline diamond compact

• US 6,676,704 B1
• Filed: 01/30/2000
• Issued: 01/13/2004
• Est. Priority Date: 08/12/1994
• 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., Blackburn, Dean C., Gardinier, Clayton F., Jensen, Kenneth M., Pope, Louis M.
• Primary Examiner(s): Isabella, David J.
• Application Number:
  US09/494,284
• Time in Patent Office: 1,444 Days
• Field of Search: 623/18.11, 623/16.11, 623/17.11, 623/20.14, 623/22.11, 623/22.21, 623/22.4, 623/33.11, 623/23.36, 623/23.88, 623/23.39, 623/23.53, 427/248.1, 427/249
• US Class Current: 623/18.11
• 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 27/04 : Metals or alloys
• CPC Class Codes: A61L 27/08 : Carbon ; Graphite
• CPC Class Codes: A61L 27/303 : Carbon
• CPC Class Codes: B22F 2207/01 : Composition gradients
• 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 2999/00 : Aspects linked to processes or compositions used in powder metallurgy
• 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
• CPC Class Codes: B22F 7/06 : of composite workpieces or articles from parts, e.g. to form tipped tools B22F7/002 takes precedence
• CPC Class Codes: C22C 26/00 : Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
• CPC Class Codes: C23C 14/0611 : Diamond
• CPC Class Codes: C23C 16/27 : Diamond only
• CPC Class Codes: F16C 33/12 : Structural composition; Use of special materials or surface treatments, e.g. for rust-proofing

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 joint component having at least one sintered polycrystalline diamond compact articulation surface and substrate surface topographical features in said polycrystalline diamond compact.

Claims

1. A component for use in a prosthetic joint, the component comprising:

a sintered polycrystalline diamond compact,

a substrate located on said polycrystalline diamond compact,

substrate surface topographical features located on said substrate, said substrate surface topographical features tending to increase surface area of contact between said substrate and a diamond table,

a diamond table sintered to said substrate on said polycrystalline diamond compact,

a gradient transition zone between said substrate and said diamond table,

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

a load bearing and articulation surface on said polycrystalline diamond compact, said load bearing and articulation surface including polycrystalline diamond, said load bearing and articulation surface being formed to present a surface that accommodates joint articulation.

2. A joint component as recited in claim 1 wherein diamond in said polycrystalline diamond compact has a coefficient of thermal expansion CTE_Cd, and wherein said substrate in said polycrystalline diamond compact has a coefficient of thermal expansion CTE_sub, and wherein CTE_Cd is not equal to CTE_sub.

3. A joint component as recited in claim 1 wherein said diamond in said polycrystalline diamond compact has a modulus M_Cd, and wherein said substrate in said polycrystalline diamond compact has a modulus M_sub, and wherein M_Cd, is not equal to M_sub.

4. A joint component as recited in claim 1 further comprising a mechanical grip between said diamond table and said substrate, said mechanical grip tending to secure said diamond table to said substrate, and said mechanical grip being present where substrate surface topographical features contact diamond.

5. A joint component as recited in claim 1 further comprising a residual stress field in said polycrystalline diamond compact that tends to enhance the strength of said polycrystalline diamond compact, characteristics of said residual stress field being determined at least in part by the nature of said substrate surface topographical features.

6. A joint component as recited in claim 1 wherein said substrate has a general surface shape;

and wherein at least some of said substrate surface topographical features protrude away from said substrate general surface shape.

7. A joint component as recited in claim 1 wherein said substrate has a general surface shape, and wherein at least some of said substrate surface topographical features are formed by substrate material that does not extend completely to said substrate general surface shape.

8. A joint component as recited in claim 5 wherein said substrate surface topographical features mitigate intensity of said stress field.

9. A joint component as recited in claim 5 wherein said substrate surface topographical features tend to distribute said stress field over a larger surface area than if said substrate surface topographical features were absent.

10. A joint component as recited in claim 9 wherein said substrate surface topographical features tend to limit peak stresss in said polycrystalline diamond compact.

11. A joint component as recited in claim 5 wherein said substrate surface topographical features serve at least in part to increase the depth of said gradient transition zone compared to the depth said gradient transition zone would have absent said substrate surface topographical features.

12. A joint component as recited in claim 6 wherein said substrate surface topographical features serve at least in part to distribute said residual stress field through a larger volume of diamond and substrate materials than if said substrate surface topographical features were not present.

13. A joint component as recited in claim 5 wherein said substrate surface topographical features serve at least in part to distribute residual stress in said polycrystalline diamond compact throughout the polycrystalline diamond compact structure in order to diminish stress per unit volume of structure compared to stress per unit volume in the polycrystalline diamond compact if said substrate surface modifications were not present.

14. A joint component as recited in claim 4 wherein said mechanical grip is created by substrate dilitation during cooling after sintering the polycrystalline diamond compact.

15. A joint component as recited in claim 4 where a dovetail is present between said diamond and said substrate in said gradient transition zone.

16. A joint component as recited in claim 1 wherein said substrate surface topographical features are selected from the group consisting of protruding and indented features.

17. A joint component as recited in claim 1 wherein said substrate surface topographical features serve at least in part to interlock said diamond table and said substrate.

18. A joint component as recited in claim 1 wherein said substrate surface topographical features serve at least in part to redistribute forces applied to the joint in order to mitigate crack formation, cleavage, and crack propagation in said diamond table.

19. A joint component as recited in claim 1 wherein said substrate surface topographical features are selected from the group consisting of waves, straight grooves, curved grooves, straight ridges, curved ridges, dimples, holes, protrusions, depressions, spherical segment depressions, spherical segment protrusions, hemispherical concave cups, hemispherical convex protrusions, partially spherical convex shapes, lines, curved lines, polygonal depressions, polygonal protrusions, cylindrical depressions, cylindrical protrusions, frusto-conical depressions, frusto-conical protrusions, waffle iron patterns and waffle patterns.

20. A prosthetic joint comprising:

a substrate that includes a solvent-catalyst metal,

substrate surface topographical features located on said substrate,

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, said mechanical grip being created at least in part by said substrate surface topographical features,

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.

21. A component as recited in claim 20 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.

22. A component as recited in claim 20 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.

23. A component as recited in claim 20 further comprising a residual stress field that tends to enhance the strength of attachment of said diamond layer to said substrate.

24. A component as recited in claim 20 further comprising substrate surface topographical features on said substrate.

25. A component as recited in claim 20 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.

26. A component as recited in claim 20 wherein diamond layer comprises 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.

27. A component as recited in claim 20 wherein said diamond load bearing and articulation surfaces is a continuous diamond surface.

28. A component as recited in claim 20 wherein said diamond load bearing and articulation surface is a discontinuous diamond surface.

29. A component as recited in claim 20 wherein said diamond load bearing and articulation surface is a segmented diamond surface.

30. A component as recited in claim 20 wherein a lip is present on said substrate in order to interlock said diamond layer to said substrate.

31. A component as recited in claim 20 further comprising CoCr solvent-catalyst metal in said diamond table interstitial spaces.

32. A component as recited in claim 20 further comprising a continuous gradient in said diamond layer.

33. A component as recited in claim 20 further comprising an incremental gradient in said diamond layer.

34. A component as recited in claim 33 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.

35. A component as recited in claim 34 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.

36. A component as recited in claim 20 further comprising an interface gradient.

37. A component as recited in claim 20 wherein said diamond layer has a thickness of from less than about 1 micron to more than about 3000 microns.