# US 7,833,274 B2 · Knee system and method of making same

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- Number: US 7,833,274 B2
- Document ID: US7833274B2
- Status: Granted
- Kind: B2
- Application number: 12/353,692
- Filed: 2009-01-14
- Published: 2009-05-14
- Granted: 2010-11-16
- Earliest claimed: 2007-05-16
- Assignees: Zimmer, Inc.
- Inventors: Oludele O. Popoola; Joel G. Scrafton
- Web page: https://patentgrep.com/patent/US7833274B2

## CPC

- A61F 2/38: for elbows or knees
- A61F 2/3094: {Designing or manufacturing processes}
- A61F 2/3859: {Femoral components}
- A61F 2/389: {Tibial components (A61F2/3868 takes precedence)}
- A61F 2002/30014: {differing in elasticity, stiffness or compressibility}
- A61F 2002/30934: {Special articulating surfaces}
- A61F 2002/30937: {with cut-outs}
- A61F 2250/0018: differing in elasticity, stiffness or compressibility
- A61F 2310/00017: Iron- or Fe-based alloys, e.g. stainless steel
- A61F 2310/00023: Titanium or titanium-based alloys, e.g. Ti-Ni alloys
- A61F 2310/00029: Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
- A61F 2310/00131: Tantalum or Ta-based alloys
- A61F 2310/00203: containing alumina or aluminium oxide
- A61F 2310/00239: containing zirconia or zirconium oxide ZrO2
- A61F 2310/00281: containing silicon carbide
- A61F 2310/00317: containing silicon nitride
- A61F 2310/0058: Coating made of diamond or of diamond-like carbon DLC
- A61F 2310/0088: Coating made of titanium nitride
- A61F 2310/00886: Coating made of chromium nitride
- 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)

## Abstract

A femoral prosthesis may be formed as a femoral component incorporating a base material and an articulating material. In one exemplary embodiment, the base material is a metal and the articulating material is a polymer. Specifically, the base material provides strength and rigidity to the femoral component, while the articulating material contacts a tibial prosthesis or natural tibia during joint articulation. In one exemplary embodiment, the articulating material forms the articulating surface of one or more condyle portions of the femoral component.

## Claims

### Claim 1

A knee prosthesis, comprising:
a femoral component formed from a non-polymeric base material and a polymer articulating material, said femoral component having at least one condyle portion formed from said non-polymeric base material, said at least one condyle portion having an upper surface, a wall at least partially defining a groove, and a lip extending from said wall into said groove, said lip and said wall of said at least one condyle portion defining an obtuse angle, said polymer articulating material received within said groove, said wall and said lip of said at least one condyle portion surrounding said polymer articulating material, wherein said lip facilitates retention of said polymer articulating material within said groove, said polymer articulating material defining an articulation surface configured for articulation against one of a proximal tibial prosthesis and a natural proximal tibia, said articulation surface of said polymer articulating material positioned substantially flush with said upper surface of said at least one condyle portion.

### Claim 2 (depends on 1)

The knee prosthesis of claim 1, wherein said non-polymeric base material comprises a metal.

### Claim 3 (depends on 2)

The knee prosthesis of claim 2, wherein said non-polymeric base material is selected from the group consisting of titanium, a titanium alloy, cobalt chromium, cobalt chromium molybdenum, stainless steel, and porous tantalum.

### Claim 4 (depends on 1)

The knee prosthesis of claim 1, wherein said non-polymeric base material comprises a ceramic.

### Claim 5 (depends on 4)

The knee prosthesis of claim 4, wherein said non-polymeric base material is selected from the group consisting of alumina, zirconia, silicon nitride, and silicon carbide.

### Claim 6 (depends on 1)

The knee prosthesis of claim 1, wherein said polymer articulating material is selected from the group consisting of poly ether ether ketone, fiber reinforced poly ether ether ketone, ultra high molecular weight polyethylene, cross-linked ultra high molecular weight polyethylene, polycarbonate urethane, polyphenylene, and polyether ketone ether ether ketone.

### Claim 7 (depends on 1)

The knee prosthesis of claim 1, wherein said articulating material is positioned in said groove by one of thermal spraying, dynamic cold spraying, insert molding, compression molding, injection molding, laser cladding, and press fitting.