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US 6,596,225 B1Granted
Methods for manufacturing a diamond prosthetic joint component
AssigneeDiamicron, Inc.
InventorsBill J. Pope, Jeffrey K. Taylor, Richard H. Dixon, Clayton F. Gardinier, Louis M. Pope, Dean C. Blackburn, Michael A. Vail, Kenneth M. Jensen
Life of this patent
Estimating the term…
Abstract
Prosthetic joints, components for prosthetic joints, superhard bearing and articulation surfaces, diamond bearing and articulation surfaces, substrate surface topographical features, materials for making joints, bearing and articulation surfaces, and methods for manufacturing and finishing the same, and related information are disclosed, including methods for manufacturing a diamond prosthetic joint component.
Claims89
A method for manufacturing a prosthetic joint component having a non-planar sintered polycrystalline diamond load bearing and articulation surface, the method comprising the steps of:
- (a) selecting a substrate material that has a modulus Msub and a coefficient of thermal expansion CTEsub, said Msub and said CTEsub not being the same as the modulus and coefficient of thermal expansion of diamond, and said Msub and said CTEsub being chosen to produce a sintered polycrystalline diamond compact that has a diamond table that is balanced with the substrate as a result of said choice of substrate material and its CTEsub, said Msub, said diamond table presenting a non-planar sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component,
- (b) forming said substrate material into a substrate geometry that will accommodate sintering with a diamond feedstock to generate a stable polycrystalline diamond compact that has a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component,
- (c) determining a desired substrate surface topography,
- (d) forming said desired substrate surface topography, said substrate surface topography serving to accommodate sintering with a diamond feedstock to generate a stable polycrystalline diamond compact that has a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component, said substrate surface topography serving to enhance bonding of a diamond table to said substrate,
- (e) selecting diamond feedstock, said diamond feedstock being selected for formation of a diamond table in a sintered polycrystalline diamond compact that presents a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component,
- (f) loading diamond feedstock for free volume reduction prior to sintering,
- (g) reducing fee volume in diamond feedstock prior to sintering said diamond feedstock with said substrate to form a sintered polycrystalline diamond compact,
- (h) preparing a pressure assembly for sintering, said pressure assembly including said substrate and said diamond feedstock in which free volume has been reduced, said pressure assembly being capable of undergoing heat and pressure to cause said substrate and said diamond feedstock to form a sintered polycrystalline diamond compact that presents a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component, and
- (i) sintering diamond feedstock and substrate into a sintered polycrystalline diamond compact that presents a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component.
6 more elements
A method for manufacturing a non-planar polycrystalline diamond load bearing and articulation surface for use a prosthetic joint, the method comprising the steps of:
- selecting an appropriate substrate material on which a table of polycrystalline diamond will be formed, said substrate material having a modulus Msub and a coefficient of thermal expansion CTEsub, said Msub and said CTEsub not being the same as the modulus and coefficient of thermal expansion of diamond, and said Msub and said CTEsub being chosen to produce a sintered polycrystalline diamond compact that has a diamond table that is balanced with the substrate as a result of said choice of substrate material and its CTEsub, said Msub, said diamond table presenting a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component,
- selecting an appropriate substrate geometry and substrate topography for forming a table of polycrystalline diamond thereon via a high temperature and high pressure sintering process,
- forming said substrate material into said selected substrate geometry and substrate topography so that said substrate will accommodate sintering with a diamond feedstock to generate a stable polycrystalline diamond compact that has a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component,
- selecting a diamond feedstock for use in combination with said substrate to form a diamond table in a sintered polycrystalline diamond compact that has a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component,
- assembling a said diamond feedstock and said substrate in a pressure transfer medium to form a pressure assembly in preparation for high temperature and high pressure sintering, and
- sintering said diamond feedstock and said substrate by subjecting said pressure assembly to heat and pressure in order cause first flow of both said substrate material, second a sweep of solvent-catalyst metal through said diamond feedstock, third flow of said diamond feedstock, and fourth coalescing of said flowed diamond feedstock into a polycrystalline diamond structure in the form of a diamond table sintered to said substrate in a sintered polycrystalline diamond compact that presents a non-planar sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component.
3 more elements
A method for manufacturing a prosthetic joint component having a non-planar sintered polycrystalline diamond load bearing and articulation surface, the method comprising the steps of:
- selecting an appropriate substrate material on which a table of polycrystalline diamond will be formed, said substrate material having a modulus Msub and a coefficient of thermal expansion CTEsub, said Msub and said CTEsub not being the same as the modulus and coefficient of thermal expansion of diamond, and said Msub and said CTEsub being chosen to produce a sintered polycrystalline diamond compact that has a diamond table that is balanced with the substrate as a result of said choice of substrate material and its CTEsub, said Msub, said diamond table presenting a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component,
- selecting an appropriate substrate geometry and substrate topography for forming a table of polycrystalline diamond thereon via a high temperature and high pressure sintering process,
- forming said substrate material into said selected substrate geometry and substrate topography so that said substrate will accommodate sintering with a diamond feedstock to generate a stable polycrystalline diamond compact that has a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component,
- selecting a diamond feedstock for use in combination with said substrate to form a diamond table in a sintered polycrystalline diamond compact that has a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component,
- assembling a said diamond feedstock and said substrate into a can in preparation for high temperature and high pressure sintering,
- sealing said can by electron beam welding, and
- sintering said diamond feedstock and said substrate by subjecting said can to heat and pressure in order cause first flow of both said substrate material, second a sweep of solvent-catalyst metal through said diamond feedstock, third flow of said diamond feedstock, and fourth coalescing of said flowed diamond feedstock into a polycrystalline diamond structure in the form of a diamond table sintered to said substrate in a sintered polycrystalline diamond compact that presents a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component.
4 more elements
A method for manufacturing a non-planar sintered polycrystalline diamond articulation surface for use in a prosthetic joint, the method comprising the steps of:
- selecting an appropriate substrate material on which a table of polycrystalline diamond will be formed, said substrate material having a modulus Msub and a coefficient of thermal expansion CTEsub, said Msub and said CTEsub not being the same as the modulus and coefficient of thermal expansion of diamond, and said Msub and said CTEsub being chosen to produce a sintered polycrystalline diamond compact that has a diamond table that is balanced with the substrate as a result of said choice of substrate material and its CTEsub, said Msub, said diamond table presenting a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component,
- selecting an appropriate substrate geometry and substrate topography for forming a table of polycrystalline diamond thereon via a high temperature and high pressure sintering process,
- forming said substrate material into said selected substrate geometry and substrate topography so that said substrate will accommodate sintering with a diamond feedstock to generate a stable polycrystalline diamond compact that has a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component,
- selecting a diamond feedstock for use in combination with said substrate to form a diamond table in a sintered polycrystalline diamond compact that has a sintered polycrystalline diamond load bearing and articulation surface that is useful in a prosthetic joint component,
- selecting a mold material for use in sintering said formed substrate and said diamond feedstock into a polycrystalline diamond compact prosthetic joint component,
- selecting a mold shape for use in said sintering of a prosthetic joint component,
- forming or obtaining said mold of said mold shape,
- assembling said diamond feedstock, said formed substrate and said mold in a pressure transfer medium to form a pressure assembly in preparation for sintering of a polycrystalline diamond compact prosthetic joint component, and
- subjecting said assembly to heat and pressure in order cause formation of sintering of a polycrystalline diamond table on said substrate in order to form a sintered polycrystalline diamond compact that presents a sintered polycrytstalline diamond prosthetic joint component load bearing and articulation surface, said mold participating in shaping of said sintered polycrytstalline diamond load bearing and articulation surface.
6 more elements
Dependencies are inferred from the claim text.