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US 12,318,299 B2Granted
Coated implant and method of making the same
AssigneeDePuy Synthes Products, Inc.
InventorsOscar A. Quintana-Ponce, Bryan J. Smith, Craig N. Ernsberger
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Abstract
An orthopaedic knee implant includes a femoral component having a substrate and a coating disposed on the surface of the substrate. A method for making a femoral component of an orthopaedic knee implant is also disclosed.
Claims23
An orthopaedic knee implant comprising:
- a femoral component configured to be coupled to a distal end of a patient's femur, the femoral component comprising
- (i) a substrate comprising a titanium alloy having (a) a condylar surface that is curved in a sagittal plane and (b) a bone-facing surface positioned opposite the condylar surface;
- and
- (ii) a coating disposed on the condylar surface, the coating comprising (a) a bonding layer comprising niobium, zirconium, titanium, tantalum, platinum, molybdenum, an alloy thereof, or combinations thereof, (b) an outer ceramic layer, and (c) a second layer comprising a plurality of alternating sublayers positioned between and interconnecting the bonding layer and the outer ceramic layer, wherein at least one sublayer of the second layer has a thickness of about 5 nm to about 500 nm, and wherein at least one sublayer of the second layer comprises at least about 95% niobium nitride,
- wherein (i) the plurality of alternating sublayers are configured to resist crack propagation from the outer ceramic layer, the plurality of alternating sublayers include a number of metallic sublayers and a number of ceramic sublayers that are harder than the metallic sublayers, and (ii) the outer ceramic layer forms an outer articular surface of the femoral component and is shaped to contact a concave proximal surface of a tibial bearing.
2 more elements
A process for forming a femoral component of an orthopaedic knee implant, the process comprising:
- depositing a first layer comprising niobium, zirconium, titanium, tantalum, platinum, molybdenum, or combinations thereof on a condylar surface of a substrate comprising titanium, wherein the condylar surface is curved in a sagittal plane;
- and
- depositing one or more alternating sublayers to form a second layer,
- wherein depositing the alternating sublayers to form the second layer comprises:
- (a) creating a sublayer of zirconium nitride on the first layer,
- (b) creating a sublayer of niobium on the sublayer of zirconium nitride, and
- (c) repeating steps (a) and (b) to form the second layer.
4 more elements
An orthopaedic knee implant comprising:
- a femoral component configured to be coupled to a distal end of a patient's femur, the femoral component comprising
- (i) a substrate comprising a titanium alloy having (a) a condylar surface that is curved in a sagittal plane and (b) a bone-facing surface positioned opposite the condylar surface;
- and
- (ii) a coating disposed on the condylar surface, the coating comprising (a) a bonding layer comprising niobium, zirconium, titanium, tantalum, platinum, molybdenum, an alloy thereof, or combinations thereof, (b) an outer ceramic layer, and (c) a second layer comprising a plurality of alternating sublayers positioned between and interconnecting the bonding layer and the outer ceramic layer, wherein the second layer comprises an inner sublayer and an outer sublayer, and wherein the second layer comprises an intermediate sublayer having a composition different from the inner sublayer, the outer sublayer, or both,
- wherein (i) the plurality of alternating sublayers are configured to resist crack propagation from the outer ceramic layer, the plurality of alternating sublayers include a number of metallic sublayers and a number of ceramic sublayers that are harder than the metallic sublayers, and (ii) the outer ceramic layer forms an outer articular surface of the femoral component and is shaped to contact a concave proximal surface of a tibial bearing.
2 more elements
Dependencies are inferred from the claim text.