Ultrasonic Bone Coating Embedding for Polymer Prosthetics
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Solution Overview
Problem
Traditional prosthetic acetabular cups with ceramic monoblock designs lack the necessary elastic modulus to match bone stiffness, leading to inadequate stress transfer and fixation, while semi-crystalline polymeric materials like UHMWPE are prone to property changes when heated, affecting strength and durability when coatings are applied.
Innovation Solution
A method and apparatus for applying a bone attachment coating using particles excited to increase their energy, allowing them to be embedded into a polymer surface without significantly heating the prosthetic component, using ultrasonic or electromagnetic energy, and applying pressure to ensure embedding without altering the polymer's properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal spray methods are used to apply coating, then coating application is effective, but the polymer material is heated above melting point causing property changes
Solution Approach 1:
The patent replaces thermal spray methods with a mechanical particle delivery system where particles are accelerated through a nozzle using compressed gas or electromagnetic fields, eliminating thermal heating while maintaining effective coating application
Solution Approach 2:
The patent employs ultrasonic vibration to excite particles before impact, enhancing their embedding capability into the polymer surface without requiring thermal heating, thus preserving material properties
2Strength
If ceramic monoblock cups are used, then stress transfer is improved, but elastic modulus does not match bone stiffness
Solution Approach 1:
The patent creates a composite structure by embedding osteoconductive particles (such as hydroxyapatite or titanium) into the polymer surface, combining the bone-matching elastic modulus of polymer with the osteointegration properties of ceramic particles
Solution Approach 2:
The patent applies osteoconductive particles selectively to the bone-facing surface region where bone attachment is needed, while the bulk polymer material maintains its bone-matching elastic modulus and mechanical properties
3Manufacturing precision
If particles are heated for embedding, then embedding effectiveness is improved, but polymer material undergoes permanent physical or chemical changes
Solution Approach 1:
The patent uses ultrasonic vibration to excite particles to high velocities before impact, enabling effective embedding into the polymer surface through mechanical energy rather than thermal heating
Solution Approach 2:
The patent replaces thermal heating methods with mechanical particle acceleration and vibration, achieving embedding effectiveness through kinetic energy and ultrasonic excitation without thermal damage to the polymer
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
The method effectively embeds osteoconductive particles into polymer surfaces of prosthetic components, enhancing bone attachment and fixation while maintaining the material's mechanical and chemical properties, enabling efficient mass production of cost-effective prosthetic cups with improved stress distribution and durability.
Implementation Method 1
exciting the particles so as to increase the energy, e.g. kinetic, vibrational and/or thermal energy, of the particles
Implementation Method 2
the energy of the particles causes localised heating of the prosthetic component such that the particles may be embedded
Data Source
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AI summary
A method and apparatus for applying a bone attachment coating to a prosthetic component, the bone attachment coating being formed from a plurality of particles applied to a surface of the prosthetic component. The method comprising: locally exciting the particles so as to increase the kinetic and/or thermal energy of the particles; and applying pressure to the particles by virtue of a press arranged so as to press the particles against the surface of the prosthetic component at an interface between the press and the prosthetic component. The kinetic and/or thermal energy of the particles causes localised heating of the component such that the particles may be embedded into the surface of the prosthetic component.