Implant Connecting Layer Dissimilar Metal Bonding

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Solution Overview

Problem

Existing artificial joint implants face challenges in securely attaching dissimilar metal components to bone contact surfaces, leading to issues like osteolysis and improper integration, which can result in implant failure and complications such as infection and pain.

Innovation Solution

A porous layer implant design featuring a connecting layer formed by dissolving a metal thin film, which includes a constituent component identical to the bone contact surface, facilitating bonding between the porous layer and the bone contact surface through hot isostatic pressing, while a detachable rib supports the porous layer to prevent twisting during attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a porous layer is attached to the bone contact surface using conventional bonding methods, then the implant can be assembled, but the bonding strength is insufficient and dissimilar metals cannot be properly integrated

Engineering Contradiction:

Improvebonding strengthVSAvoiddifficulty in bonding dissimilar metals

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

A connecting layer is introduced as an intermediary between the bone contact surface and the porous layer. This connecting layer contains at least one constituent component identical to one of the constituent components in the bone contact surface, serving as a chemical bridge that facilitates bonding between dissimilar metals. The connecting layer enables metallurgical bonding by providing compatible material interfaces on both sides.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The connecting layer is formed as a composite structure through hot isostatic pressing, combining the bone contact surface, connecting layer materials, and porous layer into an integrated composite assembly. This composite approach allows dissimilar metals to be bonded by creating a multi-material structure where each layer contributes its specific properties.

Inventive Principle:

Principle #40Composite materials

2Reliability

If the porous layer is attached firmly to the bone contact surface, then implant stability is improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveimplant stabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The bone contact surface, connecting layer, and porous layer are merged into a single integrated structure through hot isostatic pressing. This consolidation process combines multiple components into one unified implant assembly, achieving firm attachment and improved reliability while streamlining the manufacturing process by eliminating separate assembly steps for these components.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If dissimilar metals are used in the porous layer and bone contact surface, then biocompatibility and bone growth promotion are improved, but bonding between the components becomes difficult

Engineering Contradiction:

ImprovebiocompatibilityVSAvoidbonding difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The connecting layer serves as a mediator that enables bonding between dissimilar metals with different biocompatibility properties. By containing at least one constituent component identical to one in the bone contact surface, the connecting layer creates compatible bonding interfaces while allowing the porous layer to use dissimilar metals optimized for bone growth promotion and biocompatibility.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enables firm and secure attachment of dissimilar metal components to the bone contact surface, promoting natural bone growth and reducing the risk of implant-related complications like osteolysis and infection, thereby enhancing the longevity and stability of the implant.

Implementation Method 1

Methodology Applied

Scientific EffectHot isostatic pressing: Hot Isostatic Pressing

Implementation Method 2

A porous layer implant design featuring a connecting layer formed by dissolving a metal thin film

Methodology Applied

Scientific EffectDissolving:

Data Source

PatentUS10959850B2Implant having porous layer and molding method thereof

Publication Date: 2021.03.30 CORENTEC

AI summary

An implant having a porous layer and a molding method thereof includes: a substrate having a bone contact surface being in part in direct contact with a bone of a patient; a porous layer having a void inside; a connecting layer disposed between the bone contact surface and the porous layer to attach the bone contact surface to the porous layer; and a rib detachably coupled to the porous layer, wherein the connecting layer includes at least one constituent component identical to one of constituent components in the bone contact surface to be integrated into the porous layer and the bone contact surface, thereby firmly attaching the porous layer to the bone contact surface. Accordingly, bonding of dissimilar metals is facilitated by inducing the attachment of the bone contact surface of the implant to the porous layer having a void inside, formed by dissimilar metals, through the connecting layer including at least one constituent component identical to one of constituent components of the bone contact surface.