Gradient porous implant
First Claim
1. An acetabular cup comprising:
- a bearing surface; and
a shell surrounding said bearing surface, said shell having an outer generally hemispherical surface for contacting bone, said hemispherical surface having a pole and an equator, said shell having an inner solid substrate layer with a porous outer layer said porous outer layer having a first thickness and a first porosity adjacent an equatorial region of said hemispherical surface and a second thickness and a second porosity adjacent a polar region of the hemispherical surface, said second porosity and said second thickness being greater than said first porosity and said first thickness,wherein the thickness of said porous outer layer decreases substantially continuously on moving from said polar region to said equatorial region.
1 Assignment
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Accused Products
Abstract
An implantable medical device includes a porous metal foam or foam-like structure having pores defined by metal struts or webs wherein the porous structure has directionally controlled pore characteristics. The pore characteristics controlled include one or more of the metal structure porosity, pore size, pore shape, pore size distribution and strut thickness. The pore characteristics may vary in one or more directions throughout the structure. Preferably the pore characteristics are controlled to match the porous metal structure to various mechanical and biological requirements of different regions of the structure in order to optimize aspects of the implants performance and may vary not only over the surface of the porous structure but through the depth of the porous structure. The thickness of the porous metal structure may also be modified to establish a thickness profile that optimizes mechanical and biological requirements of the implants performance. Acetabular cup embodiments of the invention are described. Various methods of manufacturing implants having directionally controlled pore characteristics are described.
246 Citations
32 Claims
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1. An acetabular cup comprising:
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a bearing surface; and a shell surrounding said bearing surface, said shell having an outer generally hemispherical surface for contacting bone, said hemispherical surface having a pole and an equator, said shell having an inner solid substrate layer with a porous outer layer said porous outer layer having a first thickness and a first porosity adjacent an equatorial region of said hemispherical surface and a second thickness and a second porosity adjacent a polar region of the hemispherical surface, said second porosity and said second thickness being greater than said first porosity and said first thickness, wherein the thickness of said porous outer layer decreases substantially continuously on moving from said polar region to said equatorial region. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. An acetabular cup comprising:
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a bearing surface; and a generally hemispherical shaped shell having an inner solid substrate layer and a porous outer bone contacting layer surrounding said bearing surface, said porous outer bone contacting layer having a first porosity adjacent an equatorial region of said shell and a second porosity adjacent a polar region of said shell, said second porosity being greater than said first porosity, wherein said porous layer is thicker in said polar region than at said equatorial region, and wherein said pore size decreases continuously along said outer shell surface on moving from said polar region to said equatorial region. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31)
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32. An acetabular cup comprising:
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a bearing surface; and a shell surrounding said bearing surface, said shell having an outer generally hemispherical surface for contacting bone, said hemispherical surface having a pole and an equator, said shell having an inner solid substrate layer with a porous outer layer said porous outer layer having a first thickness and a first porosity adjacent an equatorial region of said hemispherical surface and a second thickness and a second porosity adjacent a polar region of the hemispherical surface, said second porosity and said second thickness being greater than said first porosity and said first thickness, wherein said thickness decreases sinusoidally on moving from said polar region to said equatorial region.
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Specification