Orthopaedic bearing and method for making the same

• US 7,896,921 B2
• Filed: 12/30/2004
• Issued: 03/01/2011
• Est. Priority Date: 12/30/2004
• Status: Active Grant

• Current Assignee: DePuy Synthes Products LLC (Johnson & Johnson)
• Original Assignee: Depuy Products Incorporated (Johnson & Johnson)
• Inventors: Hanes, Mark D., King, Richard, Smith, Todd S.
• Primary Examiner(s): Willse; David H
• Assistant Examiner(s): Blanco; Javier G
• Application Number:
  US11/027,099
• Publication Number:
  US 20060149387A1
• Time in Patent Office: 2,252 Days
• Field of Search: 623 1911- 1914, 623 2014- 2015, 623 2028- 2033, 623/14.12, 623/22.24, 623/22.25, 623/23.58
• US Class Current: 623/19.11
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/4081 Glenoid components, e.g. cups
• CPC Class Codes: A61F 2002/30158 trapezoidal
• CPC Class Codes: A61F 2002/30685 Means for reducing or preventing the generation of wear particulates
• CPC Class Codes: A61F 2002/30884 Fins or wings, e.g. longitudinal wings for preventing rotation within the bone cavity
• CPC Class Codes: A61F 2002/30902 laterally or radially
• CPC Class Codes: A61F 2002/30957 using a positive or a negative model, e.g. moulds
• CPC Class Codes: A61F 2002/30971 Laminates, i.e. layered products
• CPC Class Codes: A61F 2002/30973 Two joined adjacent layers having complementary interlocking protrusions and recesses
• CPC Class Codes: A61F 2002/4631 the prosthesis being specially adapted for being cemented
• CPC Class Codes: A61F 2230/0026 trapezoidal
• CPC Class Codes: A61F 2250/0057 made from both cured and uncured parts
• 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 2310/00179 Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00353 Bone cement, e.g. polymethylmethacrylate or PMMA
• CPC Class Codes: A61F 2310/00952 Coating, pre-coating or prosthesis-covering structure made of bone cement, e.g. pre-applied PMMA cement mantle
• CPC Class Codes: A61L 27/34 Macromolecular materials
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29C 43/203 : Making multilayered articles
• CPC Class Codes: B29L 2031/7532 : Artificial members, protheses
• CPC Class Codes: C08L 23/06 : Polyethene

Abstract

An orthopaedic bearing includes a metallic component having a polymer composite secured thereto. A method of making an orthopaedic bearing is also disclosed.

Claims

1. An implantable orthopaedic bearing, comprising:

a metallic component,

a non-crosslinked layer of polyethylene molded to the metallic component, and

a crosslinked layer of polyethylene having a first side and a second side, said first side of the crosslinked layer of polyethylene molded to the non-crosslinked layer of polyethylene along a melt-fused interface that is devoid of mechanical interdigitation or interlocking,

wherein said second side of the crosslinked layer of polyethylene has an articulating surface defined therein.

2. The bearing of claim 1, wherein the crosslinked layer of polyethylene comprises a gamma irradiated crosslinked layer of polyethylene.

3. The bearing of claim 1, wherein the metallic component comprises a solid metal body having a porous coating disposed thereon.

4. The bearing of claim 3, wherein:

the solid metal body defines an outer surface having the porous coating disposed thereon, and

the non-crosslinked layer of polyethylene is molded to the outer surface.

5. The bearing of claim 1, wherein the metallic component comprises a porous metal body.

6. The bearing of claim 5, wherein the non-crosslinked layer of polyethylene is molded to the porous metal body.

7. The bearing of claim 1, wherein the crosslinked layer of polyethylene and the non-crosslinked layer of polyethylene are compression molded to one another.

8. The bearing of claim 1, wherein the crosslinked layer of polyethylene and the non-crosslinked layer of polyethylene are compression molded to the metallic component.

9. The bearing of claim 1, wherein both the crosslinked layer of polyethylene and the non-crosslinked layer of polyethylene comprise ultrahigh molecular weight polyethylene.

10. An implantable orthopaedic bearing, comprising:

a metallic component,

a first layer of polyethylene molded to the metallic component, the first layer of polyethylene being crosslinked to a first degree, and

a second layer of polyethylene having a first side and a second side, said first side of the second layer of polyethylene molded to the first layer of polyethylene along a melt-fused interface that is devoid of mechanical interdigitation or interlocking, the second layer of polyethylene being crosslinked to a second degree that is different than the first degree, wherein said second side of the second layer of polyethylene has an articulating surface defined therein.

11. The bearing of claim 10, wherein the second degree is greater than the first degree.

12. The bearing of claim 10, wherein the second layer of polyethylene comprises a gamma irradiated crosslinked layer of polyethylene.

13. The bearing of claim 10, wherein the first layer of polyethylene is molded to the metallic component.

14. The bearing of claim 10, wherein the metallic component comprises a solid metal body having a porous coating disposed thereon.

15. The bearing of claim 14, wherein:

the solid metal body defines an outer surface having the porous coating disposed thereon, and

the first layer of polyethylene is molded to the outer surface.

16. The bearing of claim 10, wherein the metallic component comprises a porous metal body.

17. The bearing of claim 16, wherein the first layer of polyethylene is molded to the porous metal body.

18. The bearing of claim 10, wherein the first layer of polyethylene and the second layer of polyethylene are compression molded to one another.

19. The bearing of claim 10, wherein the first layer of polyethylene and the second layer of polyethylene are compression molded to the metallic component.

20. The bearing of claim 10, wherein both the first layer of polyethylene and the second layer of polyethylene comprise ultrahigh molecular weight polyethylene.

21. An implantable, one-piece glenoid bearing, comprising:

a metallic component,

a non-crosslinked layer of polyethylene molded to the metallic component, and

a gamma irradiated crosslinked layer of polyethylene having a first side and a second side, said first side of the crosslinked layer of polyethylene molded to the non-crosslinked layer of polyethylene along a melt-fused interface that is devoid of mechanical interdigitation or interlocking, wherein said second side of the crosslinked layer of polyethylene has an articulating surface defined therein.

22. The bearing of claim 21, wherein the crosslinked layer of polyethylene is compression molded to the non-crosslinked layer of polyethylene.

23. The bearing of claim 21, wherein the non-crosslinked layer of polyethylene is compression molded to the metallic component.

24. The bearing of claim 21, wherein the metallic component comprises a solid metal body having a porous coating disposed thereon.

25. The bearing of claim 24, wherein:

the solid metal body defines an outer surface having the porous coating disposed thereon, and

the non-crosslinked layer of polyethylene is molded to the outer surface.

26. The bearing of claim 21, wherein the metallic component comprises a porous metal body.

27. The bearing of claim 26, wherein the non-crosslinked layer of polyethylene is molded to the porous metal body.

28. The bearing of claim 21, wherein both the crosslinked layer of polyethylene and the non-crosslinked layer of polyethylene comprise ultrahigh molecular weight polyethylene.