US5522904A — Composite femoral implant having increased neck s…

Claim 1

Independent Claim 86 words

A femoral implant for a hip prosthesis comprising: a shaft oriented in a longitudinal direction; a neck extending from said shaft at an acute angle θ to the longitudinal direction; said implant comprises a plurality of layers of fibers in a matrix, wherein said fibers are substantially unidirectional in each respective layer; wherein at least 50% of said fibers of the implant are oriented in the θ direction and the remainder of said fibers of the implant are oriented in directions other than the θ angle.

Claim 2

Dependent Claim 86 words

A femoral implant for a hip prosthesis comprising: a shaft oriented in a longitudinal direction; a neck extending from said shaft at an acute angle θ to the longitudinal direction; said implant comprises a plurality of layers of fibers in a matrix, wherein said fibers are substantially unidirectional in each respective layer; wherein at least 50% of said fibers of the implant are oriented in the θ direction and the remainder of said fibers of the implant are oriented in directions other than the θ angle.

Claim 3

Dependent Claim 21 words

The implant according to claim 1, wherein about 50 to about 60% of said fibers are oriented in the θ direction.

Claim 4

Dependent Claim 21 words

The implant according to claim 1, wherein about 40 to about 50% of said fibers are oriented in the longitudinal direction.

Claim 5

Dependent Claim 14 words

The implant according to claim 1, wherein said acute angle θ is about 25°-55°.

Claim 6

Dependent Claim 13 words

The implant according to claim 1, wherein said matrix comprises a biocompatible matrix.

Claim 7

Dependent Claim 13 words

The implant according to claim 1, wherein said matrix comprises a polymeric matrix.

Claim 8

Dependent Claim 36 words

The implant according to claim 1, wherein said matrix is selected from the group consisting of polysulfone, polyethersulphone, polyarylsulfone, polyphenylene sulfide, polycarbonates, aromatic polyamides, aromatic polyamideimides, thermoplastic polyimides, polyaryletherketones, polyetheretherketones, polyarylethernitriles, aromatic polyhydroxyethers, and mixtures thereof.

Claim 9

Dependent Claim 24 words

The implant according to claim 1, wherein said matrix is selected from the group consisting of ceramics, metals, carbon, epoxies, acrylics, and mixtures thereof.

Claim 10

Dependent Claim 12 words

The implant according to claim 1, wherein said matrix comprises polysulfone resin.

Claim 11

Dependent Claim 11 words

The implant according to claim 1, wherein said fibers comprise carbon.

Claim 12

Dependent Claim 13 words

The implant according to claim 1, wherein said fibers comprise a ceramic material.

Claim 13

Dependent Claim 11 words

The implant according to claim 1, wherein said fibers comprise boron.

Claim 14

Dependent Claim 11 words

The implant according to claim 1, wherein said fibers comprise metal.

Claim 15

Dependent Claim 12 words

The implant according to claim 1, wherein said fibers comprise a polymer.

Claim 16

Dependent Claim 12 words

The implant according to claim 1, wherein said fibers comprise aramid fibers.

Claim 17

Dependent Claim 11 words

The implant according to claim 1, wherein said fibers comprise fiberglass.

Claim 18

Dependent Claim 18 words

The implant according to claim 1, wherein said remainder of said fibers are oriented in the longitudinal direction.

Claim 19

Dependent Claim 15 words

The implant according to claim 1, wherein the number of layers is at least 100.

Claim 20

Dependent Claim 14 words

The implant according to claim 1, wherein the number of layers is about 100-300.

Claim 21

Dependent Claim 19 words

The implant according to claim 1, wherein the compressive strength of the neck is at least about 80 ksi.

Claim 22

Dependent Claim 42 words

The implant according to claim 1, wherein said acute angle θ is about 25°-55°, said layers are flat, said matrix comprises a biocompatible matrix, and said fibers are selected from the group consisting of carbon, ceramic, boron, metal, aramid and fiberglass fibers.

Claim 23

Dependent Claim 37 words

The implant according to claim 1, wherein said acute angle θ is about 35°-45°, said layers are flat, said matrix comprises a biocompatible polymeric matrix, said fibers comprise carbon and the number of layers is about 100-300.

Claim 24

Dependent Claim 21 words

A femoral implant as in claim 1 wherein the remainder of the fibers are oriented within ±10° from the longitudinal direction.

Claim 25

Dependent Claim 14 words

The implant according to claim 1, wherein said acute angle θ is about 35°-45°.

Claim 26

Dependent Claim 14 words

The implant according to claim 24, wherein said acute angle θ is about 40°.

Claim 27

Dependent Claim 82 words

A femoral implant for a hip prosthesis comprising: a shaft oriented in a longitudinal-direction and a neck extending from said shaft at an acute angle θ to the longitudinal direction; wherein said implant comprises a plurality of layers of fibers in a matrix, wherein said fibers are substantially unidirectional in each respective layer; and wherein more of said fibers of the implant are oriented in the θ direction than are fibers of the implant oriented in directions other than the θ angle.

Claim 28

Dependent Claim 82 words

A femoral implant for a hip prosthesis comprising: a shaft oriented in a longitudinal-direction and a neck extending from said shaft at an acute angle θ to the longitudinal direction; wherein said implant comprises a plurality of layers of fibers in a matrix, wherein said fibers are substantially unidirectional in each respective layer; and wherein more of said fibers of the implant are oriented in the θ direction than are fibers of the implant oriented in directions other than the θ angle.

Claim 29

Dependent Claim 22 words

The implant according to claim 26, wherein more of said fibers are oriented in the θ direction than in the longitudinal direction.

Claim 30

Dependent Claim 42 words

The implant according to claim 26, wherein said acute angle θ is about 25°-55°, said layers are flat, said matrix comprises a biocompatible matrix, and said fibers are selected from the group consisting of carbon, ceramic, boron, metal, aramid and fiberglass fibers.

Claim 31

Dependent Claim 37 words

The implant according to claim 26, wherein said acute angle θ is about 35°-45°, said layers are flat, said matrix comprises a biocompatible polymeric matrix, said fibers comprise carbon and the number of layers is about 100-300.

Claim 32

Dependent Claim 77 words

A femoral implant for a hip prosthesis comprising: a shaft oriented in a longitudinal direction and a neck extending from said shaft at an acute angle θ to the longitudinal direction; wherein said implant comprises a plurality of layers of fibers in a matrix, wherein said fibers are substantially unidirectional in each respective layer; and wherein more of said layers contain fibers oriented in the θ direction than said layers contain fibers oriented in the shaft direction.

Claim 33

Dependent Claim 77 words

A femoral implant for a hip prosthesis comprising: a shaft oriented in a longitudinal direction and a neck extending from said shaft at an acute angle θ to the longitudinal direction; wherein said implant comprises a plurality of layers of fibers in a matrix, wherein said fibers are substantially unidirectional in each respective layer; and wherein more of said layers contain fibers oriented in the θ direction than said layers contain fibers oriented in the shaft direction.

Claim 34

Dependent Claim 42 words

The implant according to claim 30, wherein said acute angle θ is about 25°-55°, said layers are flat, said matrix comprises a biocompatible matrix, and said fibers are selected from the group consisting of carbon, ceramic, boron, metal, aramid and fiberglass fibers.

Claim 35

Dependent Claim 37 words

The implant according to claim 30, wherein said acute angle θ is about 35°-45°, said layers are flat, said matrix comprises a biocompatible polymeric matrix, said fibers comprise carbon and the number of layers is about 100-300.

Claim 36

Independent Claim 113 words

A method of making a femoral implant for a hip prosthesis having a shaft oriented in a longitudinal direction and a neck extending from said shaft at an acute angle θ to said longitudinal direction comprising the steps of: forming a plurality of individual layers of substantially unidirectional fibers in a matrix; stacking said layers such that at least 50% of said fibers of the implant are oriented at said angle θ and the remainder are oriented in directions other than the θ angle; heating the stacked layers under pressure to melt said matrix; cooling said matrix to form a composite block; and machining said stacked layers into the form of the implant.

Claim 37

Independent Claim 113 words

A method of making a femoral implant for a hip prosthesis having a shaft oriented in a longitudinal direction and a neck extending from said shaft at an acute angle θ to said longitudinal direction comprising the steps of: forming a plurality of individual layers of substantially unidirectional fibers in a matrix; stacking said layers such that at least 50% of said fibers of the implant are oriented at said angle θ and the remainder are oriented in directions other than the θ angle; heating the stacked layers under pressure to melt said matrix; cooling said matrix to form a composite block; and machining said stacked layers into the form of the implant.

Claim 38

Dependent Claim 42 words

The method according to claim 33, wherein said acute angle θ is about 25°-55°, said layers are flat, said matrix comprises a biocompatible matrix, and said fibers are selected from the group consisting of carbon, ceramic, boron, metal, aramid and fiberglass fibers.

Claim 39

Dependent Claim 37 words

The method according to claim 33, wherein said acute angle θ is about 35°-45°, said layers are flat, said matrix comprises a biocompatible polymeric matrix, said fibers comprise carbon and the number of layers is about 100-300.

Claim 40

Independent Claim 89 words

A method of performing hip-joint replacement surgery comprising implanting a femoral implant comprising a shaft oriented in a longitudinal direction and a neck extending from said shaft at an acute angle θ to the longitudinal direction; wherein said implant comprises a plurality of layers of fibers in a matrix wherein said fibers are unidirectional in each respective layer; and wherein at least 50% of said layers have fibers oriented in the θ direction and the remainder of said layers have fibers oriented in directions other than the θ angle.

Claim 41

Independent Claim 89 words

A method of performing hip-joint replacement surgery comprising implanting a femoral implant comprising a shaft oriented in a longitudinal direction and a neck extending from said shaft at an acute angle θ to the longitudinal direction; wherein said implant comprises a plurality of layers of fibers in a matrix wherein said fibers are unidirectional in each respective layer; and wherein at least 50% of said layers have fibers oriented in the θ direction and the remainder of said layers have fibers oriented in directions other than the θ angle.

Claim 42

Dependent Claim 42 words

The method according to claim 36, wherein said acute angle θ is about 25°-55°, said layers are flat, said matrix comprises a biocompatible matrix, and said fibers are selected from the group consisting of carbon, ceramic, boron, metal, aramid and fiberglass fibers.

Claim 43

Dependent Claim 37 words

The method according to claim 36, wherein said acute angle θ is about 35°-45°, said layers are flat, said matrix comprises a biocompatible polymeric matrix, said fibers comprise carbon and the number of layers is about 100-300.

Claim 44

Dependent Claim 85 words

A femoral implant for a hip prosthesis comprising a shaft oriented in a longitudinal direction and a neck extending from said shaft at an acute angle θ to the longitudinal direction; wherein said implant comprises a plurality of layers of fibers in a matrix, and said fibers are substantially unidirectional in each respective layer; and wherein at least 50% of the layers have fibers oriented in the θ direction and the remainder of the layers have fibers oriented in directions other than the θ angle.

Claim 45

Dependent Claim 85 words

A femoral implant for a hip prosthesis comprising a shaft oriented in a longitudinal direction and a neck extending from said shaft at an acute angle θ to the longitudinal direction; wherein said implant comprises a plurality of layers of fibers in a matrix, and said fibers are substantially unidirectional in each respective layer; and wherein at least 50% of the layers have fibers oriented in the θ direction and the remainder of the layers have fibers oriented in directions other than the θ angle.

Claim 46

Dependent Claim 35 words

A femoral implant for a hip prosthesis as claimed in claim 39 wherein the implant is made from a stack of layers of fibers and matrix so that the direction of the fibers is unbalanced.

Claim 47

Dependent Claim 30 words

A femoral implant as in claim 39 wherein more of the fibers may he oriented in the θ direction than are fibers oriented in directions other that the θ angle.

Claim 48

Dependent Claim 50 words

A femoral implant as in claim 39 wherein at least as much of the fibers are oriented in the θ direction as are fibers oriented in the shaft direction, the number of fibers oriented in the θ direction being different than the number of fibers oriented in the shaft direction.

Claim 49

Dependent Claim 43 words

A femoral implant according to claim 39, wherein said acute angle θ is about 25°-55°, said layers are flat, said matrix comprises a biocompatible matrix, and said fibers are selected from the group consisting of carbon, ceramic, boron, metal, aramid and fiberglass fibers.

Claim 50

Dependent Claim 38 words

A femoral implant according to claim 39, wherein said acute angle θ is about 35°-45°, said layers are flat, said matrix comprises a biocompatible polymeric matrix, said fibers comprise carbon and the number of layers is about 100-300.

Claim 51

Dependent Claim 21 words

A femoral implant as in claim 39 wherein the remainder of the fibers are oriented within ±10° from the longitudinal direction.

Claim 52

Dependent Claim 43 words

A femoral implant according to claim 45, wherein said acute angle θ is about 25°-55°, said layers are flat, said matrix comprises a biocompatible matrix, and said fibers are selected from the group consisting of carbon, ceramic, boron, metal, aramid and fiberglass fibers.

Claim 53

Dependent Claim 38 words

A femoral implant according to claim 45, wherein said acute angle θ is about 35°-45°, said layers are flat, said matrix comprises a biocompatible polymeric matrix, said fibers comprise carbon and the number of layers is about 100-300.

Claim 54

Independent Claim 114 words

A method of making a femoral implant for hip prosthesis having a shaft oriented in a longitudinal direction and a neck extending from said shaft at an acute angle θ to said longitudinal direction comprising the steps of: forming a plurality of individual layers of substantially unidirectional fibers in a matrix; stacking the layers such that at least 50% of the layers have fibers oriented in the θ direction and the remainder of the layers have fibers oriented in directions other than the θ angle; heating the stacked layers under pressure to melt said matrix; cooling said matrix to form a composite block; and machining said stacked layers into the form of the implant.

Claim 55

Independent Claim 114 words

A method of making a femoral implant for hip prosthesis having a shaft oriented in a longitudinal direction and a neck extending from said shaft at an acute angle θ to said longitudinal direction comprising the steps of: forming a plurality of individual layers of substantially unidirectional fibers in a matrix; stacking the layers such that at least 50% of the layers have fibers oriented in the θ direction and the remainder of the layers have fibers oriented in directions other than the θ angle; heating the stacked layers under pressure to melt said matrix; cooling said matrix to form a composite block; and machining said stacked layers into the form of the implant.

Claim 56

Dependent Claim 27 words

A method of making a femoral implant for hip prosthesis as claimed in claim 48 wherein said heating step is carried out prior to said maching step.

Claim 57

Dependent Claim 41 words

A method of making a femoral implant for hip prosthesis as claimed in claim 48 comprising sequentially said machining the stacked layers into the form of the implant and then said heating the stacked layers under pressure to melt said matrix.

Claim 58

Dependent Claim 42 words

The method according to claim 48, wherein said layers are flat, said acute angle θ is about 25°-55°, said matrix comprises a biocompatible matrix, and said fibers are selected from the group consisting of carbon, ceramic, boron, metal, aramid and fiberglass fibers.

Claim 59

Dependent Claim 37 words

The method according to claim 48, wherein said acute angle θ is about 35°-45°, said layers are flat, said matrix comprises a biocompatible polymeric matrix, said fibers comprise carbon and the number of layers is about 100-300.

Claim 60

Dependent Claim 42 words

The method according to claim 48, wherein said acute angle θ is about 25°-55°, said layers are flat, said matrix comprises a biocompatible matrix, and said fibers are selected from the group consisting of carbon, ceramic, boron, metal, aramid and fiberglass fibers.

Claim 61

Dependent Claim 37 words

The method according to claim 48, wherein said acute angle θ is about 35°-45°, said layers are flat, said matrix comprises a biocompatible polymeric matrix, said fibers comprise carbon and the number of layers is about 100-300.

Claim 62

Independent Claim 89 words

A method of performing hip-joint replacement surgery comprising implanting a femoral implant comprising a shaft oriented in a longitudinal direction and a neck extending from said shaft at an acute angle θ to the longitudinal direction; wherein said implant comprises a plurality of layers of fibers in a matrix and said fibers are unidirectional in each respective layer; and wherein at least 50% of said layers have fibers oriented in the θ direction and the remainder of said layers have fibers oriented in directions other than the θ angle.

Claim 63

Independent Claim 89 words

A method of performing hip-joint replacement surgery comprising implanting a femoral implant comprising a shaft oriented in a longitudinal direction and a neck extending from said shaft at an acute angle θ to the longitudinal direction; wherein said implant comprises a plurality of layers of fibers in a matrix and said fibers are unidirectional in each respective layer; and wherein at least 50% of said layers have fibers oriented in the θ direction and the remainder of said layers have fibers oriented in directions other than the θ angle.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1999-06-04	1999-12-04	2000-06-04	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2003-06-04	2003-12-04	2004-06-04	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2007-06-04	2007-12-04	2008-06-04	$7700.00	Window Closed / Lapsed

Composite femoral implant having increased neck strength

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