# US 10,441,684 B2 · Monolithic composite orthopedic implants and associated methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,441,684 B2 - Document ID: US10441684B2 - Status: Granted - Kind: B2 - Application number: 15/689,455 - Filed: 2017-08-29 - Published: 2018-03-15 - Granted: 2019-10-15 - Earliest claimed: 2016-09-09 - Assignees: Zimmer, Inc. - Applicants: Zimmer, Inc. - Inventors: Cristina Piecuch - Web page: https://patentgrep.com/patent/US10441684B2 ## CPC - A61L 31/022: {Metals or alloys} - A61F 2/36: Femoral heads {; Femoral endoprostheses} - A61L 27/045: {Cobalt or cobalt alloys} - A61L 27/047: {Other specific metals or alloys not covered by A61L27/042 - A61L27/045 or A61L27/06} - A61L 27/06: Titanium or titanium alloys - C04B 35/488: Composites - C04B 41/52: Multiple coating or impregnating {multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation} - Y02P 10/25: Process efficiency - 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 (preservation of bodies or disinfecting characterised by the agents employed A01N; preserving, e.g. sterilising, food or foodstuffs A23; preparations for medical, dental or toiletry purposes A61K) - A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C) - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract Implementations described herein provide for junctionless monolithic composite implants and methods for manufacturing the same. The implant includes a monolithic composite body having a first region comprising a first metal alloy, a second region comprising a second metal alloy, and a transition region disposed between the first region and the second region formed from a bonded mixture of the first alloy and the second alloy. In one example, the transition region is a sintered mixture of the first alloy and the second alloy. In another example, the transition region is disposed at a region of minimum stress within the monolithic composite body under physiological loading conditions of the implant. ## Claims ### Claim 1 An implant, comprising: a monolithic composite body having: a first region comprising a first metal alloy and including a bore disposed therein, a second region comprising a second metal alloy, and a transition region disposed between the first region and the second region, wherein the transition region comprises a sintered mixture of the first metal alloy and the second metal alloy, wherein the bore is tapered between a bore opening at an exterior surface of the first region and an interior end region of the bore, and wherein the bore further comprises a counterbore disposed in the interior end region of the bore. ### Claim 2 (depends on 1) The implant of claim 1, wherein the first metal alloy comprises a titanium alloy. ### Claim 3 (depends on 2) The implant of claim 2, wherein the second metal alloy comprises one of a cobalt chromium alloy, stainless steel, and a titanium alloy. ### Claim 4 (depends on 1) The implant of claim 1, wherein the transition region is internal to the monolithic composite body. ### Claim 5 (depends on 1) The implant of claim 1, wherein the transition region is disposed at a region of minimum stress within the monolithic composite body under physiological loading conditions of the implant. ### Claim 6 (depends on 1) The implant of claim 1, wherein the transition region defines an interlocked geometry between the first region and the second region. ### Claim 7 (depends on 1) The implant of claim 1, wherein the transition region is substantially spherical such that an outer boundary of the first region circumscribes a sphere that is interlocked with an inner boundary of the second region that defines a complementary sphere. ### Claim 8 An implant, comprising: a monolithic femoral head having: a first region formed from a first metal alloy; a second region formed from a second metal alloy and comprising a core and an articulating surface; and a transition region disposed between the first region and the second region, wherein the transition region comprises a sintered mixture of the first metal alloy and the second metal alloy, wherein the transition region defines an interlocked geometry between the first region and the second region, and wherein the transition region circumscribes a three-dimensional shape having a keyhole-shaped cross-section such that an outer boundary of the first region is interlocked with a complementary inner boundary of the second region. ### Claim 9 (depends on 8) The implant of claim 8, wherein the transition region is disposed at an area of minimum stress within the monolithic femoral head under physiological loading conditions. ### Claim 10 (depends on 8) The implant of claim 8, wherein the first metal alloy is a titanium alloy. ### Claim 11 (depends on 10) The implant of claim 10, wherein the second metal alloy is one of stainless steel, a cobalt chromium alloy, and a titanium alloy. ### Claim 12 (depends on 8) The implant of claim 8, wherein the transition region is not exposed on an exterior surface of the monolithic femoral head. ### Claim 13 (depends on 8) The implant of claim 8, wherein the first region has a bore disposed therein. ### Claim 14 (depends on 13) The implant of claim 13, wherein the bore is tapered from an exterior surface of the first region inward. ### Claim 15 (depends on 13) The implant of claim 13, wherein the bore further comprises a counterbore disposed in a bottom surface of the bore. ### Claim 16 (depends on 8) The implant of claim 8, wherein the monolithic femoral head includes voids selectively disposed within the monolithic femoral head to reduce the weight of the implant. ### Claim 17 (depends on 8) The implant of claim 8, wherein the articulating surface of the second region is polished or includes a surface coating. ### Claim 18 An implant, comprising: a monolithic femoral head having: a first region formed from a first metal alloy; a second region formed from a second metal alloy and comprising a core and an articulating surface; and a transition region disposed between the first region and the second region, wherein the transition region comprises a sintered mixture of the first metal alloy and the second metal alloy, wherein the transition region defines an interlocked geometry between the first region and the second region, and wherein the transition region is shaped such that an outer boundary of the first region circumscribes a polyhedron that is interlocked with an inner boundary of the second region that defines a mating polyhedron.