US20100136214A1 - Acetabular Shell System and Method for Making - Google Patents
Acetabular Shell System and Method for Making Download PDFInfo
- Publication number
- US20100136214A1 US20100136214A1 US12/697,847 US69784710A US2010136214A1 US 20100136214 A1 US20100136214 A1 US 20100136214A1 US 69784710 A US69784710 A US 69784710A US 2010136214 A1 US2010136214 A1 US 2010136214A1
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- United States
- Prior art keywords
- ceramic shell
- die
- mandrel
- shell
- ceramic
- Prior art date
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- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 15
- 239000000463 material Substances 0.000 claims abstract description 20
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims abstract description 19
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 claims abstract description 15
- 238000005507 spraying Methods 0.000 claims abstract description 13
- 239000000919 ceramic Substances 0.000 claims description 41
- 239000007943 implant Substances 0.000 claims description 11
- 239000002002 slurry Substances 0.000 claims description 9
- 238000005266 casting Methods 0.000 claims description 8
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 239000012530 fluid Substances 0.000 claims description 4
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- 238000007750 plasma spraying Methods 0.000 claims description 4
- 238000005245 sintering Methods 0.000 claims description 4
- 238000005498 polishing Methods 0.000 claims description 2
- 239000012255 powdered metal Substances 0.000 claims 2
- 239000011248 coating agent Substances 0.000 claims 1
- 238000000576 coating method Methods 0.000 claims 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 abstract description 21
- 239000000203 mixture Substances 0.000 abstract description 16
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 abstract description 13
- 239000010936 titanium Substances 0.000 abstract description 12
- 229910052719 titanium Inorganic materials 0.000 abstract description 12
- 239000007921 spray Substances 0.000 abstract description 6
- 239000002245 particle Substances 0.000 abstract description 4
- 230000003247 decreasing effect Effects 0.000 abstract description 2
- 238000009826 distribution Methods 0.000 abstract description 2
- 239000002826 coolant Substances 0.000 description 6
- 239000003795 chemical substances by application Substances 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 239000004698 Polyethylene Substances 0.000 description 3
- 239000011230 binding agent Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 238000005755 formation reaction Methods 0.000 description 3
- 210000001624 hip Anatomy 0.000 description 3
- -1 polyethylene Polymers 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 210000000689 upper leg Anatomy 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 241001653121 Glenoides Species 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 210000000588 acetabulum Anatomy 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical group [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 238000004320 controlled atmosphere Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000002513 implantation Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 238000001356 surgical procedure Methods 0.000 description 1
- 238000007751 thermal spraying Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
- A61L27/28—Materials for coating prostheses
- A61L27/30—Inorganic materials
- A61L27/306—Other specific inorganic materials not covered by A61L27/303 - A61L27/32
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
- A61L27/28—Materials for coating prostheses
- A61L27/30—Inorganic materials
- A61L27/32—Phosphorus-containing materials, e.g. apatite
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
- B05D1/08—Flame spraying
Definitions
- This invention relates to acetabular shells and more particularly to a method of making an implant such as an acetabular shell by free form plasma (thermal) spray technology.
- a femoral component can be inserted into the prepared femur.
- the femoral component can include a stem portion which projects into the femoral canal of the prepared femur and has an integral or separate modular head of substantially spherical shape.
- the ball-like head of the femoral component is received within an acetabular cup component which is implanted in the patient's hip socket, i.e., the acetabulum.
- the acetabular cup has a substantially hemi-spherical bearing surface for movement of the ball head of the femoral component during action of the joint.
- acetabular cups are available and it is often a multi-piece component having at least a separate outer shell and an inner liner. Where the acetabular cup has an inner liner, that inner liner is generally press-fitted into the outer shell.
- the material of the bearing surface of the acetabular cup e.g. its inner liner where present, is of the same material as that of the ball head, e.g. for a ceramic head, a ceramic bearing surface is provided (a so-called ceramic-on-ceramic prosthesis) and for a metal head, a metal bearing surface is provided (a so-called metal-on-metal prosthesis).
- the acetabular bearing surface is of polyethylene, as the acetabular cup is either provided with a polyethylene inner liner or the acetabular cup is a single component made entirely from polyethylene.
- the shape of the bearing surface into which the ball head is received affects the degree of movement available after implantation of the joint.
- a method for forming an implant includes providing a working surface such as a mandrel, and spraying the working surface with a first layer of material having a first composition such as aluminum oxide. After a suitable thickness is generated, the spray composition is gradually changed to other compositions having desired particle sizes and distribution. In one example, the composition is changed to a mixture of aluminum oxide and titanium oxide and/or titanium. As thickness builds up, the relative amount of aluminum oxide is decreased such that the composition is all titanium and titanium oxide. After a desired thickness is generated, the acetabular shell is extracted off the mandrel.
- a method of making an implant according to various features includes forming a ceramic shell having a first surface and a second surface. A first surface of the ceramic shell is located onto a mounting instrument. A layer of material is sprayed onto the second surface of the ceramic shell. The ceramic shell is then sintered.
- FIG. 1 illustrates an exemplary thermal spraying device spraying a first layer of material onto a mandrel
- FIG. 2 illustrates a cross-sectional view of the mandrel of FIG. 1 ;
- FIG. 3 illustrates a partial cross-sectional view of the spraying device and mandrel of FIG. 1 shown during an initial spraying step
- FIG. 4 illustrates the cross-sectional view of FIG. 3 , shown during an intermediate spraying step
- FIG. 5 illustrates the cross-sectional view of FIG. 4 shown during spraying of an outboard porous layer
- FIG. 6 illustrates the acetabular shell removed from the mandrel
- FIG. 7 illustrates a cross-sectional view of the acetabular shell of FIG. 6 ;
- FIG. 8 illustrates a perspective view of a ceramic casting according to a another embodiment
- FIG. 9 illustrates a perspective view of a ceramic shell removed from the casting of FIG. 8 ;
- FIG. 10 illustrates a perspective view of the ceramic shell arranged on a mandrel and a spraying device spraying a layer of material onto an outer concave surface of the ceramic shell;
- FIG. 11 illustrates a cross-sectional view of the ceramic shell having the layer of material sprayed thereon and defining an acetabular shell
- FIG. 12 illustrates the acetabular shell of FIG. 11 shown during a sintering process.
- the mandrel 10 generally defines a semi-hemispherical dome 14 and a longitudinal support portion 16 . While the mandrel 10 and spraying device 12 are shown having specific geometries, it is appreciated that they are merely exemplary and other mandrels and spraying devices may be similarly employed.
- the mandrel 10 is generally shaped inversely to a desired acetabular shell. More specifically, the mandrel 10 defines the semi-hemispherical dome 14 providing an outer convex surface 20 that corresponds to an inner concave surface of the acetabular shell.
- the thermally stable mandrel 10 may be made of tungsten.
- the outer convex surface 20 may be polished to a roughness acceptable for articulating surfaces of acetabular shells.
- the thermally stable mandrel 10 allows the generation of multiple acetabular shells without the need of individual grinding and polishing operations between subsequent shell formations.
- the mandrel 10 may be mounted on a holding fixture 22 .
- the holding fixture 22 may provide a bearing set 26 for rotational capability. Other arrangements may also be provided.
- the mandrel 10 may define a coolant channel 28 for communicating a coolant (not specifically shown) from an inlet 30 defined on the longitudinal portion 16 to an outlet 32 defined on the longitudinal portion 16 .
- the coolant channel 28 is adapted to communicate fluid through the longitudinal portion 16 , around the semi-hemispherical portion 14 and back through the longitudinal portion 16 .
- the coolant port arrangement on the mandrel 10 helps draw away heat to maintain an acceptable temperature on the outer convex surface 20 and the mandrel 10 as a whole during a spray event. It is appreciated that the coolant channel 28 may be arranged differently on the mandrel 10 and/or other cooling mechanism or techniques may be employed to maintain acceptable mandrel temperatures during use. In one example, the mandrel 10 is maintained under 200° C. Other temperatures are contemplated. In addition, while not specifically shown, heat removal may be accomplished by flow of external gases over the acetabular shell being created.
- a method of making an acetabular shell will be described.
- very fine powder of aluminum oxide 38 is sprayed onto the mandrel 10 such that a continuous layer of aluminum oxide 38 is generated on the mandrel 10 on the outer convex surface 20 .
- the very fine powder exhausted from the spraying device 12 may be in the molten, or semi-molten state.
- a mold relief agent may be applied to the mandrel 12 to facilitate removal of the acetabular shell once completed.
- a suitable thickness such as, but not limited to, less than 5 mm
- the spray concentration changes to a mixture of aluminum oxide and titanium oxide and/or titanium collectively identified at reference 40 ( FIG. 4 ).
- a suitable thickness such as, but not limited to, 5 mm
- the proportions of aluminum oxide is reduced causing the composition of titanium oxide and/or titanium to increase.
- This layer is identified at reference 42 ( FIG. 5 ).
- the thickness of layer 42 may be 3 mm, although other thicknesses are contemplated.
- the particle size of the titanium oxide and/or titanium may be increased to generate a porous outer surface. It is understood that while unique reference numerals 38 , 40 and 42 have been used to identify sequential layers of sprayed material, the relative proportions of aluminum oxide, titanium oxide and/or titanium in the sprayed material gradually change as desired. As a result, there is not necessarily any identifiable transition boundaries across the thickness of the sprayed material.
- a newly formed acetabular shell 50 is extracted off the mandrel 10 .
- the resulting acetabular shell 50 provides an inner portion 52 having a concave inner surface or articulating surface 54 of aluminum oxide, an intermediate portion 58 comprising a ceramic composition changing from aluminum oxide (from the articulating surface 54 ) to titanium and titanium oxide and finally to an outer portion 60 comprising porous titanium.
- the articulating surface of the acetabular shell 50 may then be polished to a desired roughness to serve as an articulating surface.
- other materials may be used.
- zirconia and/or other materials may be used for the aluminum oxide.
- any composition of cobalt, chromium and/or molybdenum may be used for the titanium oxide and/or titanium.
- the acetabular shell may alternatively be made exclusively of one material.
- an implant such as a stem may take the place of the mandrel 10 .
- the sequential layers may be sprayed directly onto the implant and remain on the implant as an integral feature.
- FIGS. 8-12 a method of making an acetabular shell according to an additional embodiment will be described.
- a prefabricated ceramic shell 68 ( FIG. 9 ) is used to define a template for receiving a subsequent plasma spray.
- a ceramic shell 70 may be formed by way of a casting process.
- a first and second die 72 and 74 are used to define a desired outboard surface 76 and an inboard articulating surface 78 of the ceramic shell 70 ( FIG. 9 ).
- the first die 72 defines a concave cavity 80 and the second die 74 defines a convex extension surface 82 .
- the concave cavity 80 defines a plurality of outward knobs 86 .
- the outward knobs 86 are operable to define a textured surface, represented as dimples 90 on the outboard surface 76 of the cast ceramic shell 68 ( FIG. 9 ).
- the convex extension surface 82 is operable to define the inboard articulating surface 78 of the cast ceramic shell 68 .
- the walls of the concave cavity 80 are coated with titanium powder such that a layer of titanium is defined on outboard surface 76 of the cast ceramic shell 68 .
- a slurry of ceramic 92 is delivered to the first and second die 72 and 74 .
- the slurry of ceramic 92 may be created in a fluid with binders and deflocculating agents as desired.
- the particle size of the ceramic, the quantity of binder and deflocculating agents and the ratio of various components in the slurry may be adjusted to achieve a slurry providing favorable casting properties. While the respective die cavities 72 and 74 are shown in an open position in FIG. 8 , it is appreciated that the slurry of ceramic 92 may be delivered through a port to a closed die cavity.
- the ceramic shell 68 defines a hemispherical dome 96 . It is appreciated that other shapes may be alternatively formed. It is further appreciated that while the textured surface is depicted as dimples 90 , the first die 72 may be configured to define any textured surface including, but not limited to, ridges, notches and other configurations. Furthermore, while the formation of the ceramic shell 68 has been described by way of a casting process, other fabrication techniques may be used. Once the ceramic shell 68 has been cast, the ceramic shell 68 is dried or semi-dried into a stable dome 98 . In one example, the process of converting the ceramic shell 68 to a semi-dried, stable dome 98 may be achieved in a baking oven 100 . The baking oven 100 is operable to drive off any excess fluid slurry. Furthermore, any binders and/or deflocculating agents may or may not be removed.
- the stable dome 98 may be placed onto a mandrel 110 .
- the mandrel 110 may cooperate with a longitudinal support portion 116 , a holding fixture 122 and a bearing set 126 .
- the mandrel 110 may include a coolant channel 128 . Again, other configurations may be employed.
- a layer of titanium oxide 140 is sprayed with a plasma sprayer 12 to a desired thickness.
- mechanical interlocking is achieved between the titanium oxide 140 and the outboard textured surface 90 of the ceramic dome 98 .
- the interface between the textured surface 90 and the titanium oxide 140 resists torsional slippage and radial slippage of the titanium oxide 140 relative the outboard surface 76 of the ceramic dome 98 .
- a sinter cycle may be performed as follows. First, the oven temperature may be raised to 175° C. at 5° C./min. The 175° C. may be maintained for 4 hours. The temperature may be ramped to a peak temperature such as 1650° C. at 5° C./min (optionally lower temperatures may be used i.e. 1300° C.-1450° C.). The peak temperature may be maintained for 8 hours. It is appreciated that a peak temperature of 1300° C.-1450° C. may be maintained for longer periods than higher temperatures (such as 1650° C.). The temperature may be ramped down to 600° C. at 5° C./min. The 600° C. temperature may be held for 30 minutes.
- a peak temperature such as 1650° C. at 5° C./min.
- the 600° C. temperature may be held for 30 minutes.
- ramp rate, dwell time and dwell temperatures (collectively referred to as variables) of the sinter cycle may define other ranges.
- the variable assigned during the sinter process may be chosen to discourage crack formation in the structure.
- a thermally induced compressive stress may be generated in the ceramic structure to discourage premature failure.
- the concave inner surface 78 may be polished to a desired roughness to serve as an articulating surface.
Abstract
A method for forming an acetabular shell includes providing a working surface such as a mandrel, and spraying the working surface with a first layer of material having a first composition such as aluminum oxide. After a suitable thickness is generated, the spray composition is gradually changed to other compositions having desired particle sizes and distribution. In one example, the composition is changed to a mixture of aluminum oxide and titanium oxide and/or titanium. As thickness builds up, the relative amount of aluminum oxide is decreased such that the composition is all titanium and titanium oxide. After a desired thickness is generated, the acetabular shell is extracted off the mandrel.
Description
- This application is a continuation of U.S. patent application Ser. No. 11/366,727 filed Mar. 2, 2006, which claims the benefit of a U.S.
Provisional Application 60/658,407 filed on Mar. 3, 2005. The disclosure of the above application is incorporated herein by reference. - This invention relates to acetabular shells and more particularly to a method of making an implant such as an acetabular shell by free form plasma (thermal) spray technology.
- In replacement hip surgery a femoral component can be inserted into the prepared femur. The femoral component can include a stem portion which projects into the femoral canal of the prepared femur and has an integral or separate modular head of substantially spherical shape. The ball-like head of the femoral component is received within an acetabular cup component which is implanted in the patient's hip socket, i.e., the acetabulum. The acetabular cup has a substantially hemi-spherical bearing surface for movement of the ball head of the femoral component during action of the joint.
- Various designs of acetabular cups are available and it is often a multi-piece component having at least a separate outer shell and an inner liner. Where the acetabular cup has an inner liner, that inner liner is generally press-fitted into the outer shell. In some designs of hip prostheses the material of the bearing surface of the acetabular cup, e.g. its inner liner where present, is of the same material as that of the ball head, e.g. for a ceramic head, a ceramic bearing surface is provided (a so-called ceramic-on-ceramic prosthesis) and for a metal head, a metal bearing surface is provided (a so-called metal-on-metal prosthesis). In some other designs, the acetabular bearing surface is of polyethylene, as the acetabular cup is either provided with a polyethylene inner liner or the acetabular cup is a single component made entirely from polyethylene. The shape of the bearing surface into which the ball head is received affects the degree of movement available after implantation of the joint.
- A method for forming an implant includes providing a working surface such as a mandrel, and spraying the working surface with a first layer of material having a first composition such as aluminum oxide. After a suitable thickness is generated, the spray composition is gradually changed to other compositions having desired particle sizes and distribution. In one example, the composition is changed to a mixture of aluminum oxide and titanium oxide and/or titanium. As thickness builds up, the relative amount of aluminum oxide is decreased such that the composition is all titanium and titanium oxide. After a desired thickness is generated, the acetabular shell is extracted off the mandrel.
- A method of making an implant according to various features includes forming a ceramic shell having a first surface and a second surface. A first surface of the ceramic shell is located onto a mounting instrument. A layer of material is sprayed onto the second surface of the ceramic shell. The ceramic shell is then sintered.
- Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
- The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
-
FIG. 1 illustrates an exemplary thermal spraying device spraying a first layer of material onto a mandrel; -
FIG. 2 illustrates a cross-sectional view of the mandrel ofFIG. 1 ; -
FIG. 3 illustrates a partial cross-sectional view of the spraying device and mandrel ofFIG. 1 shown during an initial spraying step; -
FIG. 4 illustrates the cross-sectional view ofFIG. 3 , shown during an intermediate spraying step; -
FIG. 5 illustrates the cross-sectional view ofFIG. 4 shown during spraying of an outboard porous layer; -
FIG. 6 illustrates the acetabular shell removed from the mandrel; -
FIG. 7 illustrates a cross-sectional view of the acetabular shell ofFIG. 6 ; -
FIG. 8 illustrates a perspective view of a ceramic casting according to a another embodiment; -
FIG. 9 illustrates a perspective view of a ceramic shell removed from the casting ofFIG. 8 ; -
FIG. 10 illustrates a perspective view of the ceramic shell arranged on a mandrel and a spraying device spraying a layer of material onto an outer concave surface of the ceramic shell; -
FIG. 11 illustrates a cross-sectional view of the ceramic shell having the layer of material sprayed thereon and defining an acetabular shell; and -
FIG. 12 illustrates the acetabular shell ofFIG. 11 shown during a sintering process. - The following description of the embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. Moreover, while the description below is directed to an acetabular shell, the teachings described herein may similarly be employed to form other implants, such as, but not limited to femoral implants, tibial implants, tibial trays, and glenoid implants.
- With initial reference now to
FIGS. 1 and 2 , a thermally stable mandrel and plasma spraying device are shown and identified atreference mandrel 10 generally defines asemi-hemispherical dome 14 and alongitudinal support portion 16. While themandrel 10 andspraying device 12 are shown having specific geometries, it is appreciated that they are merely exemplary and other mandrels and spraying devices may be similarly employed. - The
mandrel 10 is generally shaped inversely to a desired acetabular shell. More specifically, themandrel 10 defines thesemi-hemispherical dome 14 providing anouter convex surface 20 that corresponds to an inner concave surface of the acetabular shell. In one example, the thermallystable mandrel 10 may be made of tungsten. Theouter convex surface 20 may be polished to a roughness acceptable for articulating surfaces of acetabular shells. The thermallystable mandrel 10 allows the generation of multiple acetabular shells without the need of individual grinding and polishing operations between subsequent shell formations. - With specific reference to
FIG. 2 , themandrel 10 may be mounted on aholding fixture 22. Theholding fixture 22 may provide abearing set 26 for rotational capability. Other arrangements may also be provided. - The
mandrel 10 may define acoolant channel 28 for communicating a coolant (not specifically shown) from aninlet 30 defined on thelongitudinal portion 16 to anoutlet 32 defined on thelongitudinal portion 16. As shown, thecoolant channel 28 is adapted to communicate fluid through thelongitudinal portion 16, around thesemi-hemispherical portion 14 and back through thelongitudinal portion 16. The coolant port arrangement on themandrel 10 helps draw away heat to maintain an acceptable temperature on theouter convex surface 20 and themandrel 10 as a whole during a spray event. It is appreciated that thecoolant channel 28 may be arranged differently on themandrel 10 and/or other cooling mechanism or techniques may be employed to maintain acceptable mandrel temperatures during use. In one example, themandrel 10 is maintained under 200° C. Other temperatures are contemplated. In addition, while not specifically shown, heat removal may be accomplished by flow of external gases over the acetabular shell being created. - With continued reference to
FIGS. 1 and 2 and additional reference toFIG. 3 , a method of making an acetabular shell according to the present teachings will be described. In a controlled atmosphere, very fine powder ofaluminum oxide 38 is sprayed onto themandrel 10 such that a continuous layer ofaluminum oxide 38 is generated on themandrel 10 on theouter convex surface 20. The very fine powder exhausted from thespraying device 12 may be in the molten, or semi-molten state. In one example, prior to applying thealuminum oxide 38, a mold relief agent may be applied to themandrel 12 to facilitate removal of the acetabular shell once completed. - Once a suitable thickness (such as, but not limited to, less than 5 mm) of
aluminum oxide 38 is sprayed onto themandrel dome 14, the spray concentration changes to a mixture of aluminum oxide and titanium oxide and/or titanium collectively identified at reference 40 (FIG. 4 ). After a suitable thickness is generated (such as, but not limited to, 5 mm), the proportions of aluminum oxide is reduced causing the composition of titanium oxide and/or titanium to increase. This layer is identified at reference 42 (FIG. 5 ). The thickness oflayer 42 may be 3 mm, although other thicknesses are contemplated. - Concurrently, the particle size of the titanium oxide and/or titanium may be increased to generate a porous outer surface. It is understood that while
unique reference numerals - Turning now to
FIG. 6 , once a suitable thickness is achieved (such as, but not limited to, 13 mm), a newly formedacetabular shell 50 is extracted off themandrel 10. The resultingacetabular shell 50 provides aninner portion 52 having a concave inner surface or articulatingsurface 54 of aluminum oxide, anintermediate portion 58 comprising a ceramic composition changing from aluminum oxide (from the articulating surface 54) to titanium and titanium oxide and finally to anouter portion 60 comprising porous titanium. The articulating surface of theacetabular shell 50 may then be polished to a desired roughness to serve as an articulating surface. It is appreciated that other materials may be used. For example, zirconia and/or other materials may be used for the aluminum oxide. Likewise, any composition of cobalt, chromium and/or molybdenum may be used for the titanium oxide and/or titanium. In addition, the acetabular shell may alternatively be made exclusively of one material. - In another embodiment, an implant such as a stem may take the place of the
mandrel 10. As a result, the sequential layers may be sprayed directly onto the implant and remain on the implant as an integral feature. - Turning now to
FIGS. 8-12 , a method of making an acetabular shell according to an additional embodiment will be described. In this embodiment, rather than forming all layers of an acetabular shell by way of plasma spraying, a prefabricated ceramic shell 68 (FIG. 9 ) is used to define a template for receiving a subsequent plasma spray. - As shown in
FIG. 8 , aceramic shell 70 may be formed by way of a casting process. In one example, a first and second die 72 and 74 are used to define a desiredoutboard surface 76 and aninboard articulating surface 78 of the ceramic shell 70 (FIG. 9 ). As illustrated inFIG. 8 , thefirst die 72 defines aconcave cavity 80 and thesecond die 74 defines aconvex extension surface 82. Theconcave cavity 80 defines a plurality ofoutward knobs 86. The outward knobs 86 are operable to define a textured surface, represented asdimples 90 on theoutboard surface 76 of the cast ceramic shell 68 (FIG. 9 ). Theconvex extension surface 82 is operable to define theinboard articulating surface 78 of the castceramic shell 68. In one example, the walls of theconcave cavity 80 are coated with titanium powder such that a layer of titanium is defined onoutboard surface 76 of the castceramic shell 68. - During the casting process, a slurry of ceramic 92 is delivered to the first and second die 72 and 74. In one example, the slurry of ceramic 92 may be created in a fluid with binders and deflocculating agents as desired. The particle size of the ceramic, the quantity of binder and deflocculating agents and the ratio of various components in the slurry may be adjusted to achieve a slurry providing favorable casting properties. While the
respective die cavities FIG. 8 , it is appreciated that the slurry of ceramic 92 may be delivered through a port to a closed die cavity. - As shown in
FIG. 9 , theceramic shell 68 defines ahemispherical dome 96. It is appreciated that other shapes may be alternatively formed. It is further appreciated that while the textured surface is depicted asdimples 90, thefirst die 72 may be configured to define any textured surface including, but not limited to, ridges, notches and other configurations. Furthermore, while the formation of theceramic shell 68 has been described by way of a casting process, other fabrication techniques may be used. Once theceramic shell 68 has been cast, theceramic shell 68 is dried or semi-dried into astable dome 98. In one example, the process of converting theceramic shell 68 to a semi-dried,stable dome 98 may be achieved in abaking oven 100. The bakingoven 100 is operable to drive off any excess fluid slurry. Furthermore, any binders and/or deflocculating agents may or may not be removed. - Turning now to
FIG. 10 , thestable dome 98 may be placed onto amandrel 110. Themandrel 110 may cooperate with alongitudinal support portion 116, a holdingfixture 122 and abearing set 126. Furthermore, themandrel 110 may include acoolant channel 128. Again, other configurations may be employed. - Next, a layer of
titanium oxide 140 is sprayed with aplasma sprayer 12 to a desired thickness. As best illustrated inFIG. 11 , mechanical interlocking is achieved between thetitanium oxide 140 and the outboardtextured surface 90 of theceramic dome 98. The interface between thetextured surface 90 and thetitanium oxide 140 resists torsional slippage and radial slippage of thetitanium oxide 140 relative theoutboard surface 76 of theceramic dome 98. - With reference now to
FIG. 12 , a newly formedacetabular shell 150 is then placed into abaking oven 100 for a sintering process. In one example, a sinter cycle may be performed as follows. First, the oven temperature may be raised to 175° C. at 5° C./min. The 175° C. may be maintained for 4 hours. The temperature may be ramped to a peak temperature such as 1650° C. at 5° C./min (optionally lower temperatures may be used i.e. 1300° C.-1450° C.). The peak temperature may be maintained for 8 hours. It is appreciated that a peak temperature of 1300° C.-1450° C. may be maintained for longer periods than higher temperatures (such as 1650° C.). The temperature may be ramped down to 600° C. at 5° C./min. The 600° C. temperature may be held for 30 minutes. - It is appreciated that the sintering procedure explained above is merely exemplary. As such, ramp rate, dwell time and dwell temperatures (collectively referred to as variables) of the sinter cycle may define other ranges. The variable assigned during the sinter process may be chosen to discourage crack formation in the structure. In one example, a thermally induced compressive stress may be generated in the ceramic structure to discourage premature failure.
- Once the
acetabular shell 150 is sintered, the concaveinner surface 78 may be polished to a desired roughness to serve as an articulating surface. - While the invention has been described in the specification and illustrated in the drawings with reference to various embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as defined in the claims. Furthermore, the mixing and matching of features, elements and/or functions between various embodiments is expressly contemplated herein so that one of ordinary skill in the art would appreciate from this disclosure that features, elements and/or functions of one embodiment may be incorporated into another embodiment as appropriate, unless described otherwise above. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out this invention, but that the invention will include any embodiments falling within the foregoing description and the appended claims.
Claims (5)
1. A method of making an implant for use in replacing a portion of a patient's joint, the method comprising:
providing a first die defining a concave cavity having a textured die surface;
providing a second die defining a convex extension surface, the first and second die collectively forming a die cavity;
coating the textured die surface with powdered metal;
injecting a slurry of material into the die cavity;
casting the slurry of material thereby forming a ceramic shell;
removing the ceramic shell from the die cavity, the ceramic shell having a first surface and a second surface, the second surface being formed of metal from the powdered metal;
driving off excess fluid slurry by converting the ceramic shell to a stable dome in an oven;
locating the stable dome onto a mounting instrument;
plasma spraying a layer of material onto an outer surface of the stable dome that corresponds to the second surface of the ceramic shell; and
sintering the ceramic shell.
2. The method of claim 1 , further comprising polishing the second surface of the ceramic shell.
3. The method of claim 1 wherein forming the ceramic shell comprises casting a ceramic shell having a textured outboard surface having a plurality of dimples, the textured outboard surface adapted to accept the sprayed layer of material.
4. The method of claim 3 wherein plasma spraying the layer of material comprises spraying titanium oxide onto the second surface of the ceramic shell.
5. The method of claim 1 wherein the textured die surface includes a plurality of outwardly extending knobs
Priority Applications (1)
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US12/697,847 US20100136214A1 (en) | 2005-03-03 | 2010-02-01 | Acetabular Shell System and Method for Making |
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US65840705P | 2005-03-03 | 2005-03-03 | |
US11/366,727 US7655162B2 (en) | 2005-03-03 | 2006-03-02 | Acetabular shell system and method for making |
US12/697,847 US20100136214A1 (en) | 2005-03-03 | 2010-02-01 | Acetabular Shell System and Method for Making |
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US20100136214A1 true US20100136214A1 (en) | 2010-06-03 |
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US12/697,847 Abandoned US20100136214A1 (en) | 2005-03-03 | 2010-02-01 | Acetabular Shell System and Method for Making |
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US11/366,727 Expired - Fee Related US7655162B2 (en) | 2005-03-03 | 2006-03-02 | Acetabular shell system and method for making |
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US (2) | US7655162B2 (en) |
DE (1) | DE112006000507B4 (en) |
GB (1) | GB2438345B (en) |
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US10278711B2 (en) | 2006-02-27 | 2019-05-07 | Biomet Manufacturing, Llc | Patient-specific femoral guide |
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CN113270166A (en) * | 2021-05-07 | 2021-08-17 | 北京长木谷医疗科技有限公司 | Acetabular fossa grinding and filing method, device, grinding and filing tool and storage medium |
Also Published As
Publication number | Publication date |
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GB2438345B (en) | 2011-01-05 |
DE112006000507T5 (en) | 2008-01-17 |
US20060198943A1 (en) | 2006-09-07 |
WO2006094270A2 (en) | 2006-09-08 |
GB2438345A (en) | 2007-11-21 |
US7655162B2 (en) | 2010-02-02 |
GB0717096D0 (en) | 2007-10-17 |
DE112006000507B4 (en) | 2016-06-16 |
WO2006094270A3 (en) | 2007-12-13 |
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