Knee prosthesis of an alloy ceramic composite

Abstract

The invention relates to a kind of alloy ceramic composite knee joint prosthesis and its preparation method.The prosthesis is composed of femoral condyle and tibial plateau, both of which are made of alloy and ceramic composite material, the bottom of tibial plateau is made of alloy with high strength and wear resistance, and the top of tibial plateau is made of alloy and ceramic material mixed and made by 3D printing.The preparation process combines powder metallurgy and 3D printing technology to ensure the accurate distribution and structure of the material.In addition, the shape and size of the prosthesis can be customized according to the needs of the patient to achieve better matching and functional recovery.

Description

Technical Field

[0001] This invention relates to a knee joint prosthesis made of alloy ceramic composite material, and more particularly to an improved knee joint prosthesis for knee replacement surgery. Background Technology

[0002] Traditional knee prostheses are typically made of a single material, such as titanium alloys or cobalt-chromium-molybdenum alloys for the tibial plateau and femoral condyle. To reduce friction between the two, a spacer made of ceramic or high-molecular-weight polyethylene is placed between them, connecting the spacer and the tibial plateau via a mechanical structure. However, in practical use, slippage easily occurs between the spacer and the tibial plateau, causing the spacer to detach from the tibial plateau. This increases wear on both the femoral condyle and the spacer, and over time, the spacer may even dislodge, leading to paralysis of the entire knee prosthesis and requiring revision knee replacement surgery. This separate design of the tibial plateau and spacer has limitations in terms of wear resistance, biocompatibility, and customization. Therefore, it is necessary to provide a knee prosthesis with improved performance and customizable features to enhance the stability of the knee joint. Summary of the Invention

[0003] To address the limitations of existing knee joint prostheses, this invention provides a knee joint prosthesis made of alloy-ceramic composite material. This prosthesis improves stability by eliminating the separate spacer design and fusing the spacer with the tibial plateau, thus avoiding the need for secondary knee replacement.

[0004] To achieve the above objectives, the present invention provides a knee joint prosthesis made of alloy-ceramic composite material, characterized in that it comprises: a tibial plateau and a femoral condyle, both of which are made of alloy-ceramic composite material. The bottom of the tibial plateau is made of a high-strength and wear-resistant alloy, and the top of the tibial plateau is made of a mixture of alloy and ceramic materials and manufactured by 3D printing. The alloy content of the top of the tibial plateau gradually decreases uniformly from 100% to 0% from bottom to top, while the ceramic content gradually increases uniformly from 0% to 100%, so that the surface material of the tibial plateau in contact with the femoral condyle is 100% ceramic. (See attached figure.) Figure 4 As shown: The density of the lines represents the concentration of titanium alloy powder. The concentration of titanium alloy is higher near the bottom and higher near the top. In the direction perpendicular to the artificial articular surface of the femoral condyle, the concentration of titanium alloy gradually and uniformly decreases from 100% to 0% from the inside out, while the concentration of ceramic gradually and uniformly increases from 0% to 100%, ensuring that the surface material in contact with the tibial plateau is 100% ceramic. Figure 6As shown in Figure 201, the density of the dots represents the content of alloy powder. The proportion of ceramic powder is high at the end of the femoral condyle near the tibial plateau, while the proportion of alloy is high at the other end. This ensures reduced wear and, due to the integrated structure, increases the stability of the knee prosthesis and reduces the risk of knee prosthesis replacement.

[0005] Furthermore, the alloy may be a Ti-6Al-4v titanium alloy or a CoCrMo cobalt-chromium-molybdenum alloy.

[0006] Furthermore, the ceramic material includes zirconia ceramic or alumina ceramic to provide excellent wear resistance and biocompatibility.

[0007] Furthermore, the preparation process of the alloy ceramic composite material includes a combination of powder metallurgy technology and 3D printing technology to achieve precise material distribution and structure.

[0008] Furthermore, the shape and size of the prosthesis can be customized to meet the individual needs of the patient to provide a better fit and functional recovery.

[0009] Furthermore, the surfaces of the tibial plateau and femoral condyle that contact the human skeleton have micro / nanoscale surface textures to promote osteoblast growth and osseointegration. Micro / nanoscale surface textures refer to fine bumps, grooves, or structures at the micro and nanoscale levels on the material surface. These textures can be prepared using various methods, including acid pickling, sandblasting, chemical etching, and electrochemical corrosion. Micro / nanoscale surface textures include extremely small microstructures, such as nanoscale particles, pores, or pits, as well as tiny grooves at the microscopic level. These structures increase surface area, providing more contact points, which helps osteoblast attachment and promotes growth, while also improving the mechanical anchoring force between the prosthesis and the surrounding bone.

[0010] This one-piece knee prosthesis effectively eliminates the problem of pad detachment. During use, the femoral condyle and tibial plateau are in direct contact, and because both contact surfaces are equipped with ceramic structures, friction between them can be effectively reduced.

[0011] A method for preparing an alloy-ceramic composite knee joint prosthesis, comprising the knee joint prosthesis described in any one of the above-mentioned methods, includes the following steps: Detailed models of knee prostheses, including alloy and ceramic components, were created using computer-aided design (CAD) software. Choose Ti-6Al-4v or CoCrMo as the titanium alloy powder printing material, and choose zirconium oxide or alumina as the ceramic powder printing material. Ti-6Al-4v or CoCrMo alloy powder is mixed with zirconium oxide or alumina ceramic powder in a predetermined ratio to obtain the desired composite material. Using selective laser melting (SLM) or electron beam melting (EBM) 3D printing technology, mixed materials are stacked layer by layer to form the shape of a knee joint prosthesis. The 3D printing process can stack powder and melt it layer by layer according to the CAD design model to form a solid structure. After 3D printing is completed, powder metallurgy technology is used to sinter and heat treat the prosthesis to eliminate residual stress and improve the mechanical properties of the material. The surface of the implant is sandblasted, polished, or acid-washed to ensure a smooth surface suitable for implantation.

[0012] In summary, this application includes at least one of the following beneficial effects: First, the integrated design of the tibial plateau and the spacer can effectively improve the stability of the knee prosthesis, prevent the spacer from falling off and requiring a second implantation, and extend the lifespan of the prosthesis.

[0013] Secondly, with the help of medical-engineering interaction platforms and 3D printing technology, personalized customization can be achieved, making up for individual differences in human body structure, better adapting to the patient's body, and reducing discomfort. Attached Figure Description

[0014] The illustrations and descriptions in the accompanying drawings are helpful for understanding the present invention: Figure 1 This is an assembly diagram of a knee joint prosthesis made of titanium alloy ceramic composite material; Figure 2 This is a front view of the tibial plateau; Figure 3 This is a top view of the tibial plateau; Figure 4 This is a cross-sectional view of the tibial plateau; Figure 5 This is a front view of the femoral condyle; Figure 6 It is a cross-sectional view of the femoral condyle; The above figures include the following reference numerals: 10, tibial plateau; 101, top of tibial plateau; 102, tibial plateau claw; 103, composite material part of tibial plateau; 20, femoral condyle; 201, composite material part of femoral condyle. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0016] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0017] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0018] Specific Implementation Example 1: As shown in the example Figure 1-6As shown: The composite material prosthesis includes a tibial plateau 10 and a femoral condyle 20. Both the tibial plateau and the femoral condyle are made of titanium alloy-ceramic composite material. The bottom of the tibial plateau is made of high-strength and wear-resistant titanium alloy, and the top 101 of the tibial plateau is made of a mixture of titanium alloy and ceramic material through 3D printing. From bottom to top, the titanium alloy content of the top of the tibial plateau gradually decreases uniformly from 100% to 0%, while the ceramic content gradually increases uniformly from 0% to 100%, so that the surface material in contact with the femoral condyle is 100% ceramic. The tibial plateau has a triangular vertebral structure at its bottom 102 for easy implantation. The top of the tibial plateau has a concave surface that conforms to the femoral condyle protrusion. Along the femoral condyle, perpendicular to the artificial joint surface, the concentration of titanium alloy gradually decreases uniformly from 100% to 0%, while the concentration of ceramic gradually increases uniformly from 0% to 100%, ensuring that the surface material in contact with the tibial plateau is 100% ceramic. This reduces wear while increasing the stability of the knee prosthesis due to its integrated structure, thus lowering the risk of knee replacement. During manufacturing, the spacer between the tibial plateau and femoral condyle is eliminated. The surface in contact with the femoral condyle is made of ceramic, effectively solving the problem of spacer detachment. To ensure the stability of the ceramic contact surface and prevent detachment, ceramic and titanium alloy are mixed in a specific concentration ratio and then 3D printed to form a composite material, effectively enhancing the overall stability of the knee joint.

[0019] Specific Embodiment 2: The composite material prosthesis includes a tibial plateau 10 and a femoral condyle 20. Both the tibial plateau and the femoral condyle are made of cobalt-chromium-molybdenum alloy ceramic composite material. The bottom of the tibial plateau is made of a high-strength and wear-resistant cobalt-chromium-molybdenum alloy, and the top 101 of the tibial plateau is made of a mixture of cobalt-chromium-molybdenum alloy and ceramic material and manufactured by 3D printing. The content of cobalt-chromium-molybdenum alloy in the top of the tibial plateau gradually decreases uniformly from 100% to 0% from bottom to top, while the content of ceramic gradually decreases from 0% to 100%. The concentration of cobalt-chromium-molybdenum alloy gradually and uniformly decreases from 100% to 0% along the artificial joint surface, while the concentration of ceramic gradually and uniformly increases from 0% to 100%, making the surface material in contact with the tibial plateau 102 102 100% ceramic. The bottom of the tibial plateau 102 has a triangular vertebral structure for easy implantation into the human body. The top of the tibial plateau has a concave surface that fits the protrusion of the femoral condyle. The concentration of cobalt-chromium-molybdenum alloy in the femoral condyle gradually and uniformly decreases from 100% to 0% along the inner to outer surface, while the concentration of ceramic gradually and uniformly increases from 0% to 100%, making the surface material in contact with the tibial plateau 100% ceramic.

[0020] Specific Embodiment 3: To save costs, the composite materials of the femoral condyle and tibial plateau can be chosen selectively. For example, the tibial plateau can be made of a composite material of titanium alloy and ceramic, while the femoral condyle can be made of titanium alloy; or, the femoral condyle can be made of a composite material of titanium alloy and ceramic, while the tibial plateau can be made of titanium alloy. This embodiment will reduce manufacturing difficulty and costs.

[0021] In combination with any of the above embodiments, the ceramic powder material can be zirconia ceramic or alumina ceramic to provide excellent wear resistance. The size of the entire knee joint prosthesis can be customized with the help of a medical engineering interaction platform and 3D printing technology, solving the problem of different knee joint sizes in different people.

Claims

1. A knee joint prosthesis made of alloy-ceramic composite material, characterized in that, include: The tibial plateau (10) and femoral condyle (20) are both made of alloy ceramic composite material. The bottom (102) of the tibial plateau is made of high-strength and wear-resistant alloy, and the top (101) of the tibial plateau is made of alloy and ceramic material mixed and 3D printed. The alloy content of the top of the tibial plateau gradually decreases uniformly from 100% to 0% from bottom to top, and the ceramic content gradually increases uniformly from 0% to 100%, so that the surface material of the tibial plateau in contact with the femoral condyle is 100% ceramic. The concentration of alloy in the femoral condyle (20) in the direction perpendicular to the artificial joint surface gradually decreases uniformly from 100% to 0% from the inside to the outside, and the concentration of ceramic gradually increases uniformly from 0% to 100%, so that the surface material in contact with the tibial plateau is 100% ceramic. While ensuring reduced wear, the integrated structure increases the stability of the knee joint prosthesis and reduces the risk of knee joint prosthesis replacement.

2. The knee joint prosthesis according to claim 1, characterized in that, The alloy can be a titanium alloy or a cobalt-chromium-molybdenum alloy.

3. The knee joint prosthesis according to claim 1, characterized in that, The ceramic material includes zirconia ceramic or alumina ceramic to provide excellent wear resistance and biocompatibility.

4. The knee joint prosthesis according to claim 1, characterized in that, The preparation process of the alloy ceramic composite material includes a combination of powder metallurgy technology and 3D printing technology to achieve precise material distribution and structure.

5. The knee joint prosthesis according to claim 1, characterized in that, The shape and size of the prosthesis can be customized to meet the individual needs of the patient, providing a better fit and functional recovery.

6. The knee joint prosthesis according to claim 1 or 2, characterized in that, The surfaces of the tibial plateau and femoral condyle that come into contact with human bones have micro- and nano-scale surface textures, which promote bone cell growth and bone integration.

7. A method for preparing the alloy-ceramic composite knee joint prosthesis according to claim 1, characterized in that, Includes the following steps: Detailed models of knee prostheses, including alloy and ceramic components, were created using computer-aided design (CAD) software. Alloy powder and ceramic powder are mixed in a predetermined ratio to obtain the desired composite material; Using selective laser melting (SLM) or electron beam melting (EBM) 3D printing technologies, mixed materials are stacked layer by layer to form the shape of a knee joint prosthesis. The 3D printing process can stack powder and melt it layer by layer according to the CAD design model to form a solid structure. After 3D printing is completed, the prosthesis is sintered and heat-treated to eliminate residual stress and improve the mechanical properties of the material. The surface of the implant is sandblasted, polished, or acid-washed to ensure a smooth surface suitable for implantation.

Images