# US 9,259,508 B2 · Ceramic manufactures

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 9,259,508 B2
- Document ID: US9259508B2
- Status: Granted
- Kind: B2
- Application number: 11/220,997
- Filed: 2005-09-07
- Published: 2006-02-02
- Granted: 2016-02-16
- Earliest claimed: 2003-03-07
- Assignees: Louis A. Serafin, Jr. Trust; Xylon LLC
- Applicants: Louis A. Serafin, Jr.; Gerald J. Jerry, Jr.; Nicholas H. Burlingame
- Inventors: Louis A. Serafin, Jr.; Gerald J. Jerry, Jr.; Nicholas H. Burlingame
- Web page: https://patentgrep.com/patent/US9259508B2

## CPC

- A61L 27/10: Ceramics or glasses
- A61F 2/3094: {Designing or manufacturing processes}
- A61F 2/3859: {Femoral components}
- B28B 3/003: {Pressing by means acting upon the material via flexible mould wall parts, e.g. by means of inflatable cores, isostatic presses (isostatic presses in general B30B5/02)}
- B28B 11/003: {the shaping of preshaped articles, e.g. by bending (B28B11/08 takes precedence)}
- B28B 11/08: for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
- B28B 11/24: for curing, setting or hardening (processes for influencing or modifying the setting or hardening ability of mortars, concrete or artificial stone compositions, in general C04B40/00)
- A61C 13/0003: {Making bridge-work, inlays, implants or the like}
- A61F 2/38: for elbows or knees
- A61F 2/3877: {Patellae or trochleae}
- A61F 2/4425: {made of articulated components}
- A61F 2/4684: {Trial or dummy prostheses}
- A61F 2002/30133: {kidney-shaped or bean-shaped}
- A61F 2002/30433: {using additional screws, bolts, dowels, rivets or washers e.g. connecting screws}
- A61F 2002/30492: {using a locking pin}
- A61F 2002/30604: {modular}
- A61F 2002/30616: {Sets comprising a plurality of prosthetic parts of different sizes or orientations}
- A61F 2002/3071: {Identification means; Administration of patients}
- A61F 2002/30736: {Augments or augmentation pieces, e.g. wedges or blocks for bridging a bone defect}
- A61F 2002/30841: {Sharp anchoring protrusions for impaction into the bone, e.g. sharp pins, spikes}
- A61F 2002/30843: {Pyramidally-shaped}
- A61F 2002/30892: {parallel}
- A61F 2002/30968: {Sintering}
- A61F 2002/30991: {Mandibular components}
- A61F 2002/3895: {unicompartimental}
- A61F 2002/4205: {Tibial components}
- A61F 2002/4207: {Talar components}
- A61F 2220/0025: Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
- A61F 2220/0041: using additional screws, bolts, dowels or rivets, e.g. connecting screws
- A61F 2230/0015: Kidney-shaped, e.g. bean-shaped
- A61F 2250/0089: coded with symbols, e.g. dots, numbers, letters, words
- A61F 2310/00185: based on metal oxides
- A61F 2310/00197: containing magnesia or magnesium oxide
- A61F 2310/00239: containing zirconia or zirconium oxide ZrO2
- A61F 2310/00592: Coating or prosthesis-covering structure made of ceramics or of ceramic-like compounds
- 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)
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- A61C: DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE (non-driven toothbrushes A46B; {tongue scrapers A61B17/24;} preparations for dentistry A61K6/00; preparations for cleaning the teeth or mouth A61K8/00, A61Q11/00)

## Abstract

Ceramic bodies can be made by providing an initial green body of ceramic; and machining the initial green body to provide a machined green ceramic body. Embedding the initial green body in an embedding mass can be avoided. The initial green body can be bisqued, infiltrated an adjuvant such as machining wax, removing the infiltrated body, and machining it. Highly detailed ceramic products can be generated. The machined green ceramic body may be fired and/or further processed to provide a more finished ceramic body. Examples include a femoral component for a posterior stabilized knee implant, a component body for an artificial rotation device containing knee implant prosthesis a dental implant or bridge, an ice skating blade, and so forth. Zirconia ceramics are advantageously employed, for an example, Mg-TTZ.

## Claims

### Claim 1

An article of manufacture comprising a prosthetic implant or prosthetic implant component of Mg-TTZ ceramic, which is made of or to include the Mg-TTZ ceramic by a method that includes providing a bisqued initial green body of ceramic by providing a powdered ceramic material, which substantially is a monoclinic zirconia having magnesium oxide for a stabilizer, and, without employing a binder additional to the powdered ceramic to do so:
compressing the material in its powder form through a cold isostatic press operation to form a raw, pressed initial green body, and then heating the raw, pressed initial green body to a bisque stage to provide the bisqued initial green body; and, after the foregoing steps are carried out without employing a binder additional to the powdered ceramic material, carrying out the following further steps:
without embedding the bisqued initial green body of ceramic in an embedding mass, machining the bisqued initial green body to provide a machined, bisqued green ceramic body such that the machined, bisqued green ceramic body has a shape, which is a precursor shape essentially analogous to, being of the same proportions as, the shape of, but larger than, the ceramic portion of a fired predetermined finished ceramic body prosthetic implant or prosthetic implant component; and then firing the machined, bisqued green ceramic body to provide a fired Mg-TTZ ceramic body product, which is the same size and shape or essentially the same size and shape as the ceramic portion of the fired predetermined finished ceramic body prosthetic implant or prosthetic implant component.

### Claim 2 (depends on 1)

The article of claim 1, wherein the prosthetic implant or prosthetic implant component is a femoral or tibial component for a replacement knee joint.

### Claim 3 (depends on 2)

The article of claim 2, which is a femoral component for a posterior stabilized knee implant, said component embracing an Mg-TTZ ceramic mass including a frame having side walls and a top that bridge left and right condylar flanges that have condyles including anterior, inferior and posterior condyles, which form an intracondylar notch; and a posterior stabilizing stop within said notch; and said component being of one piece.

### Claim 4 (depends on 2)

The article of claim 2, which is a femoral frame component for a rotation device containing knee implant, said component embracing a one-piece fired ceramic frame of the Mg-TTZ, having side walls and a front wall residing in an intracondylar notch between lateral and medial anterior, inferior and posterior condylar flanges, which flanges have corresponding articular surfaces plus a trochlear surface essentially between said anterior flanges and respective anterior condyles, said walls able to receive a depending, rotating male part that can be engaged by a receptacle in a corresponding tibial tray.

### Claim 5 (depends on 2)

The article of claim 2, which is a cruciate-retaining femoral component for a knee implant, said component embracing an Mg-TTZ ceramic mass including a smooth, patella-tracking articular surface anteriorly between left and right condylar flanges that have condyles, said condyles including left and right inferior and posterior condyles between which inferior and posterior condyles there is an empty intracondylar notch; and said component being of one piece.

### Claim 6 (depends on 2)

The article of claim 2, which is a unicompartmental femoral condylar component for a knee, said component embracing an Mg-TTZ ceramic mass including a smooth, articular condylar surface, which includes anterior, inferior and posterior condyles; and said component being of one piece.

### Claim 7 (depends on 3)

The article of claim 3, which has a strength against a posterior condyle of said femoral component of at least about 1500 pounds (about 0.68 metric tons) when tested according to United States Food and Drug Administration standards corresponding to standards for strength testing on a posterior condyle of a metal femoral knee component in which force is applied in a posterior to anterior direction on an unsupported portion of the posterior condyle.

### Claim 8 (depends on 4)

The article of claim 4, which has a strength against a posterior condyle of said femoral frame component of at least about 1500 pounds (about 0.68 metric tons) when tested according to United States Food and Drug Administration standards corresponding to standards for strength testing on a posterior condyle of a metal femoral knee component in which force is applied in a posterior to anterior direction on an unsupported portion of the posterior condyle.

### Claim 9 (depends on 5)

The article of claim 5, which has a strength against a posterior condyle of said femoral component of at least about 1500 pounds (about 0.68 metric tons) when tested according to United States Food and Drug Administration standards corresponding to standards for strength testing on a posterior condyle of a metal femoral knee component in which force is applied in a posterior to anterior direction on an unsupported portion of the posterior condyle.

### Claim 10 (depends on 6)

The article of claim 6, which has a strength against a posterior condyle of said femoral condylar component of at least about 1500 pounds (about 0.68 metric tons) when tested according to United States Food and Drug Administration standards corresponding to standards for strength testing on a posterior condyle of a metal femoral knee component in which force is applied in a posterior to anterior direction on an unsupported portion of the posterior condyle.

### Claim 11 (depends on 1)

The article of claim 1, which is selected from the group consisting of a one-piece unicompartmental knee spacer device; a multi-piece unicompartmental joint aligning device; a temporal mandibular joint cap implant; a patellofemoral joint implant; a vertebra cap; an ankle joint ensemble or component; a bridge, a tooth or teeth; and an intermediary articulation plate for a tibial tray and liner, or said plate assembled in combination with said tray.

### Claim 12 (depends on 2)

The article of claim 2, which is light-transmissive so as to provide for rapid setting of surgical cement by use of illumination passed through the article.

### Claim 13 (depends on 1)

The article of claim 1, which has a density of at least about 98 percent of theoretical, without HIP treatment.

### Claim 14 (depends on 13)

The article of claim 13, wherein the density is at least about 99 percent of theoretical, without HIP treatment.