Titanium alloy with oxidized zirconium for a prosthetic implant
First Claim
1. A method of forming a prosthetic implant wherein said implant comprises a first titanium articulating member having a first bearing surface and a second articulating member having a second bearing surface forming an articulable joint with said first bearing surface, said method comprising:
- depositing a coating of zirconium on at least a portion of said first bearing surface;
heating said coating in an inert atmosphere; and
heating said coating in the presence of oxygen, after heating said coating in an inert atmosphere;
wherein the method results in an outer zirconium oxide layer, an inner titanium-zirconium diffusion layer, and an intermediate layer consisting essentially of zirconium, between the outer zirconium oxide layer and the inner titanium-zirconium diffusion layer, such that the inner titanium-zirconium diffusion layer prevents delamination.
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Accused Products
Abstract
A prosthetic device having a generally fixed member formed from a low friction material such as ultra-high molecular weight polyethylene and an articulating titanium member, which includes an articular bearing surface. The articular surface is a zirconium oxide layer formed by applying a coating of zirconium onto the titanium member and heating this in an oxygen-containing environment. This causes the zirconium to oxidize and further causes the zirconium to migrate into the titanium member forming a titanium zirconium diffusion layer, which prevents delamination.
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Citations
20 Claims
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1. A method of forming a prosthetic implant wherein said implant comprises a first titanium articulating member having a first bearing surface and a second articulating member having a second bearing surface forming an articulable joint with said first bearing surface, said method comprising:
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depositing a coating of zirconium on at least a portion of said first bearing surface; heating said coating in an inert atmosphere; and heating said coating in the presence of oxygen, after heating said coating in an inert atmosphere; wherein the method results in an outer zirconium oxide layer, an inner titanium-zirconium diffusion layer, and an intermediate layer consisting essentially of zirconium, between the outer zirconium oxide layer and the inner titanium-zirconium diffusion layer, such that the inner titanium-zirconium diffusion layer prevents delamination. - View Dependent Claims (2, 3, 4, 5, 8, 9, 10, 11, 12, 13, 14, 15)
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6. A method of preparing a wear-resistant bearing surface on a prosthetic implant, the prosthetic implant comprising a titanium surface or a titanium alloy surface, the method comprising:
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depositing onto said titanium or titanium alloy surface a coating of zirconium; heating said coating on said titanium or titanium alloy surface in an inert atmosphere; and heating said coating on said titanium or titanium alloy surface in the presence of oxygen, after heating said coating on said titanium or titanium alloy surface in an inert atmosphere; said method effective to cause an outer portion of said coating to form a zirconium oxide layer, an inner portion of said coating to diffuse unoxidized zirconium into said titanium or titanium alloy surface, and an intermediate portion of said coating, consisting essentially of zirconium, to remain unoxidized throughout said step of heating in the presence of oxygen, said method effective to prevent delamination. - View Dependent Claims (7)
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16. A method of preparing a zirconium-oxide surface on a prosthetic implant substrate, the prosthetic implant substrate comprising a titanium substrate surface or a titanium alloy substrate surface comprising:
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depositing onto said substrate surface a coating of zirconium; pre-heating the coated substrate surface to a first temperature in an inert atmosphere; exposing the coated substrate surface to oxygen; and heating the coated substrate surface to a second temperature for a period of time in the presence of said oxygen, said heating step effective to form an outer zirconium oxide layer that will not delaminate. - View Dependent Claims (17, 18, 19, 20)
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Specification