US 6,610,095 B1Granted

Prosthetic joint having substrate surface topographical featurers and at least one diamond articulation surface

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

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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 a prosthetic joint having substrate surface topographical features and at least one diamond articulation surface.

Claims71

Dependent claims

A prosthetic joint component comprising

a substrate that includes a solvent-catalyst metal,
a diamond layer sintered to said substrate,
a zone between said substrate and said diamond layer that has a composition gradient of decreasing solvent-catalyst metal content across said zone,
chemical bonds in said zone, said chemical bonds including diamond-to-diamond bonds in said diamond table, diamond-to-metal bonds in said gradient transition zone, and metal-to-metal bonds in said solvent-catalyst metal,
a mechanical grip between said diamond layer and said substrate which tends to secure said diamond layer to said substrate,
interstitial spaces in said diamond layer,
solvent-catalyst metal present in said interstitial spaces,
substrate surface topographical features serving to interlock said substrate and said diamond table, and
a non-planar load bearing and articulation surface formed by said diamond layer.

6 more elements

A prosthetic joint comprising:

a first joint member,
a first joint member bone fixation portion, said first joint member bone fixation portion being adapted to be securable to a bone,
a first joint member load bearing and articulation portion,
a first joint member polycrystalline diamond compact, said first joint member polycrystalline diamond compact serving to form at least a portion of said first joint member load bearing and articulation portion,
a first joint member polycrystalline diamond compact substrate, said substrate being located on said first joint member polycrystalline diamond compact,
a first joint member polycrystalline diamond compact diamond table sintered to said first joint member polycrystalline diamond compact substrate,
solvent-catalyst metal located in said first joint member polycrystalline diamond compact,
a first joint member gradient transition zone between said first joint member polycrystalline diamond compact substrate and said first joint member polycrystalline diamond compact diamond table, said first joint member gradient transition zone having a substrate side and a diamond table side, said first joint member gradient transition zone having both solvent-catalyst metal and diamond therein, and said first joint member gradient transition zone exhibiting a transition of ratios of percentage content of solvent-catalyst metal to diamond from one side of said gradient transition zone to another side such that at a first point in said first joint member gradient transition zone near said substrate side, the ratio of percentage content of solvent-catalyst metal to diamond is greater than it is at a second point in said first joint member gradient transition zone closer to said diamond side than said first point,
chemical bonds between said first joint member polycrystalline diamond compact diamond table and said first joint member polycrystalline diamond compact substrate which tend to secure said diamond table to said substrate,
a mechanical grip between said first joint member polycrystalline diamond compact diamond table and said first joint member polycrystalline diamond compact substrate which tends to secure said diamond table to said substrate,
a first joint member load bearing and articulation surface, said first joint member load bearing and articulation surface including sintered polycrystalline diamond of said first joint member polycrystalline diamond compact, said sintered polycrystalline diamond providing a smooth and low-friction first joint member load bearing and articulation surface,
a second joint member,
a second joint member bone fixation portion, said second joint member bone fixation portion being adapted to be securable to a bone,
a second joint member load bearing and articulation portion,
a second joint member polycrystalline diamond compact, said second joint member polycrystalline diamond compact serving to form at least a portion of said second joint member load bearing and articulation portion,
a second joint member polycrystalline diamond compact substrate, said substrate being located on said second joint member polycrystalline diamond compact,
a second joint member polycrystalline diamond compact diamond table sintered to said second joint member polycrystalline diamond compact substrate,
solvent-catalyst metal located in said second joint member polycrystalline diamond compact,
a second joint member gradient transition zone between said second joint member polycrystalline diamond compact substrate and said second joint member polycrystalline diamond compact diamond table, said second joint member gradient transition zone having a substrate side and a diamond table side, said second joint member gradient transition zone having both solvent-catalyst metal and diamond therein, and said second joint member gradient transition zone exhibiting a transition of ratios of percentage content of solvent-catalyst metal to diamond from one side of said gradient transition zone to another side such that at a first point in said second joint member gradient transition zone near said substrate side, the ratio of percentage content of solvent-catalyst metal to diamond is greater than it is at a second point in said second joint member gradient transition zone closer to said diamond side than said first point,
chemical bonds between said second joint member polycrystalline diamond compact diamond table and said second joint member polycrystalline diamond compact substrate which tend to secure said diamond table to said substrate,
a mechanical grip between said second joint member polycrystalline diamond compact diamond table and said second joint member polycrystalline diamond compact substrate which tends to secure said diamond table to said substrate, and
a second joint member load bearing and articulation surface, said second joint member load bearing and articulation surface including sintered polycrystalline diamond of said second joint member polycrystalline diamond compact, said sintered polycrystalline diamond providing a smooth and low-friction second joint member load bearing and articulation surface;
wherein at least one of said substrates has surface topographical features located on it, said topographical features serving to enhance said mechanical grip between the substrate and its corresponding diamond table.

20 more elements

A prosthetic joint comprising:

a first joint member,
a first joint member bone fixation portion, said first joint member bone fixation portion being adapted to be securable to a bone,
a first joint member load bearing and articulation portion,
a second joint member,
a second joint member bone fixation portion, said second joint member bone fixation portion being adapted to be securable to a bone,
a second joint member load bearing and articulation portion,
a second joint member polycrystalline diamond compact, said second joint member polycrystalline diamond compact serving to form at least a portion of said second joint member load bearing and articulation portion,
a second joint member polycrystalline diamond compact substrate, said substrate being located on said second joint member polycrystalline diamond compact,
a second joint member polycrystalline diamond compact diamond table sintered to said second joint member polycrystalline diamond compact substrate,
solvent-catalyst metal located in said second joint member polycrystalline diamond compact,
a second joint member gradient transition zone between said second joint member polycrystalline diamond compact substrate and said second joint member polycrystalline diamond compact diamond table, and
a second joint member load bearing and articulation surface, said second joint member load bearing and articulation surface including sintered polycrystalline diamond, said sintered polycrystalline diamond providing a smooth and low-friction second joint member load bearing and articulation surface;
wherein at least one of substrates includes topographical features located on it, said topographical features serving to enhance said mechanical grip between the substrate and its corresponding diamond table.

10 more elements

Dependencies are inferred from the claim text.