Composite prosthetic bearing having a crosslinked articulating surface and method for making the same

• US 7,819,925 B2
• Filed: 01/28/2002
• Issued: 10/26/2010
• Est. Priority Date: 01/28/2002
• Status: Expired due to Fees

• Current Assignee: DePuy Synthes Products LLC (Johnson & Johnson)
• Original Assignee: Depuy Products Incorporated (Johnson & Johnson)
• Inventors: McNulty, Donald E., King, Richard, Smith, Todd S.
• Primary Examiner(s): RAMANA, ANURADHA
• Application Number:
  US10/058,495
• Publication Number:
  US 20030144741A1
• Time in Patent Office: 3,193 Days
• Field of Search: 623/19.11, 623/19.13, 623/20.22, 623/20.23, 623/20.33, 623/21.13, 623/21.16, 623/22.16, 623/22.17, 623/22.18, 623/22.24, 623/23.59, 623/23.58, 623/23.4, 623/23.43
• US Class Current: 623/23.58
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2/34 Acetabular cups
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/4081 Glenoid components, e.g. cups
• CPC Class Codes: A61F 2002/30133 kidney-shaped or bean-shaped
• CPC Class Codes: A61F 2002/30367 with additional means for preventing said rotation
• CPC Class Codes: A61F 2002/30403 Longitudinally-oriented cooperating ribs and grooves on mating lateral surfaces of a mainly longitudinal connection
• CPC Class Codes: A61F 2002/30822 Circumferential grooves
• CPC Class Codes: A61F 2002/30827 Plurality of grooves
• 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 2002/30971 Laminates, i.e. layered products
• CPC Class Codes: A61F 2002/3412 with pins or protrusions, e.g. non-sharp pins or protrusions projecting from a shell surface
• CPC Class Codes: A61F 2002/4631 the prosthesis being specially adapted for being cemented
• 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 2230/0015 Kidney-shaped, e.g. bean-shaped
• CPC Class Codes: A61F 2310/00011 Metals or alloys
• CPC Class Codes: A61L 27/16 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: A61L 27/48 with macromolecular fillers
• CPC Class Codes: B29C 35/08 : by wave energy or particle radiation B29C64/00, B29C71/04 take precedence
• CPC Class Codes: B29C 43/003 : characterised by the choice of material
• CPC Class Codes: B29C 43/52 : Heating or cooling
• CPC Class Codes: B29K 2023/0683 : UHMWPE, i.e. ultra high molecular weight polyethylene
• CPC Class Codes: B29K 2105/24 : crosslinked or vulcanised
• CPC Class Codes: B29K 2105/243 : Partially cured
• CPC Class Codes: B29K 2623/0683 : UHMWPE, i.e. ultra high molecular weight polyethylene
• CPC Class Codes: B29K 2995/0083 : Creep
• CPC Class Codes: B29K 2995/0087 : Wear resistance
• CPC Class Codes: B29K 2995/0089 : Impact strength or toughness
• CPC Class Codes: B29L 2009/00 : Layered products
• CPC Class Codes: B29L 2031/7532 : Artificial members, protheses
• CPC Class Codes: B32B 27/16 : specially treated, e.g. irradiated
• CPC Class Codes: C08J 3/245 : Differential crosslinking of one polymer with one crosslinking type, e.g. surface crosslinking
• CPC Class Codes: C08J 3/28 : Treatment by wave energy or particle radiation
• CPC Class Codes: C08L 23/06 : Polyethene

Abstract

An implantable prosthetic bearing is constructed of a composite material having a first layer and second layer. The first layer has an articulating surface defined therein, whereas the second layer has a engaging surface defined therein for engaging either another prosthetic component or the bone itself The first layer of the implantable prosthetic bearing is constructed of crosslinked polymer such as Ultra-High Molecular Weight Polyethylene, whereas the second layer of the implantable prosthetic bearing is constructed of polymer such as Ultra-High Molecular Weight Polyethylene that is either non-crosslinked or crosslinked to a lesser degree than the first layer. In such a manner, the first layer possesses mechanical properties which are advantageous in regard to the articulating surface (e.g., enhanced wear and oxidation resistance), whereas the second layer possesses mechanical properties which are advantageous in regard to the engaging surface (e.g., high ductility, toughness, and creep resistance). A method of making a prosthetic bearing is also disclosed.

Claims

1. An implantable orthopaedic prosthesis, comprising:

a laminar composite bearing having (i) a radiation crosslinked, quenched layer of polyethylene having an articulating surface defined in a first side thereof; and

(ii) a non-crosslinked layer of polyethylene molded to a second, opposite side of said crosslinked, quenched layer of polyethylene at a melt fused interface, wherein non-crosslinked polyethylene of the non-crosslinked layer of polyethylene is fused to crosslinked, quenched polyethylene of the crosslinked layer of polyethylene at the melt-fused interface.

2. The implantable orthopaedic prosthesis of claim 1, wherein said radiation crosslinked, quenched layer of polyethylene and said non-crosslinked layer of polyethylene are compression molded to one another.

3. The implantable orthopaedic prosthesis of claim 1, wherein:

said non-crosslinked layer of polyethylene has an engaging surface defined therein which is adapted to be secured to an acetabulum of a patient.

4. The implantable bearing of claim 1, wherein:

said crosslinked layer of polymer has an articulating surface defined therein, and

said non-crosslinked layer of polymer has an engaging surface defined therein which is adapted to be secured to a glenoid of a patient.

5. The implantable bearing of claim 1, wherein:

said crosslinked layer of polymer has an articulating surface defined therein, and

said non-crosslinked layer of polymer has an engaging surface defined therein which is adapted to be secured to a tibia of a patient.

6. The implantable orthopaedic prosthesis of claim 1, wherein said radiation crosslinked, quenched layer of polyethylene comprises a radiation crosslinked, annealed layer of polyethylene.

7. An implantable orthopaedic prosthesis, comprising:

a laminar composite bearing having (i) a first layer of polyethylene having an articulating surface defined in a first side thereof; and

(ii) a second layer of polyethylene molded to a second, opposite side of said first layer of polyethylene at a melt-fused interface, wherein (a) said first layer of polyethylene is radiation crosslinked to a first degree and quenched (b) said second layer of polyethylene is radiation crosslinked to a second degree that is different than said first degree and quenched, and (c) polyethylene crosslinked to the second degree of the second layer of polyethylene is fused to polyethylene crosslinked to the first degree of the first layer of polyethylene at the melt-fused interface.

8. The implantable orthopaedic prosthesis of claim 7, wherein said second degree is less than said first degree.

9. The implantable orthopaedic prosthesis of claim 7, wherein said first layer of polyethylene and said second layer of polyethylene are compression molded to one another.

10. The implantable orthopaedic prosthesis of claim 7, wherein:

said second layer of polyethylene has an engaging surface defined therein which is adapted to be secured to an acetabulum of a patient.

11. The implantable bearing of claim 7, wherein:

said first layer of polyethylene has an articulating surface defined therein, and

said second layer of polyethylene has an engaging surface defined therein which is adapted to be secured to a glenoid of a patient.

12. The implantable bearing of claim 7, wherein:

said first layer of polyethylene has an articulating surface defined therein, and

said second layer of polyethylene has an engaging surface defined therein which is adapted to be implanted into a tibia of a patient.

13. The implantable orthopaedic prosthesis of claim 7, wherein said first layer of polyethylene and said second layer of polyethylene comprise crosslinked, annealed polyethylene.