Manufacturing and material processing for prosthetic devices
First Claim
1. A method of manufacturing a meniscus prosthetic device, comprising:
- injection molding a core having an upper surface, a lower surface opposite the upper surface, and an outer surface disposed between the upper and lower surfaces, the outer surface defining a plurality of recesses;
winding reinforcing fiber into at least one of the plurality of recesses of the outer surface; and
injection molding an outer portion around the outer surface and the reinforcing fibers to secure the reinforcing fibers therein.
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Accused Products
Abstract
Methods of manufacturing prosthetic devices for use as an artificial meniscus are disclosed. In some embodiments, the methods include injection molding a resilient core material, tensioning reinforcing fibers around the injection molded core, and injection molding an outer layer to embed the reinforcing fibers within the prosthetic device. In some instances the core material is a polycarbonate polyurethane and the reinforcing fibers are made of ultra-high molecular weight polyethylene (UHMWPE) having a lower melting temperature than the polyurethane. In one particular embodiment, the core material is Bionate 80A and the reinforcing fibers are made of Dyneema. In other embodiments, methods for manufacturing a reinforced material for use in prosthetic devices is disclosed.
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Citations
20 Claims
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1. A method of manufacturing a meniscus prosthetic device, comprising:
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injection molding a core having an upper surface, a lower surface opposite the upper surface, and an outer surface disposed between the upper and lower surfaces, the outer surface defining a plurality of recesses; winding reinforcing fiber into at least one of the plurality of recesses of the outer surface; and injection molding an outer portion around the outer surface and the reinforcing fibers to secure the reinforcing fibers therein. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A method of manufacturing a prosthetic device, the method comprising:
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injecting a polycarbonate polyurethane into a mold to form a core, the mold comprising a mirror polished upper molding surface for defining an upper surface of the core, a mirror polished lower molding surface for defining a lower surface of the core, and one or more removable inserts for defining a plurality of recesses of the core; removing the one or more removable inserts; winding ultra high molecular weight polyethylene reinforcing fiber around the core and into at least one of the plurality of recesses of the core; heating the core; injecting a polycarbonate polyurethane into the mold to form an outer layer surrounding the core and the reinforcing fiber; and cooling the mold. - View Dependent Claims (18, 19)
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20. A method of forming a meniscus implant, comprising:
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injecting a polymer into a mold to form a core, the mold comprising a mirror polished upper molding surface for defining an upper surface of the core, a mirror polished lower molding surface for defining a lower surface of the core, and one or more removable inserts for defining a plurality of recesses around a perimeter of the core; removing the one or more removable inserts; winding reinforcing fiber around the core and into the plurality of recesses of the core, the reinforcing fiber tensioned with a force between about 5 N and about 78 N during the winding; and injecting a polymer into the mold to form an outer layer surrounding the core and the reinforcing fiber.
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Specification