Patent ID: 9718241
Date: 2017-08-01
CPC Classifications: A61B,A61F,A61L,B29C

Claim:
1. A method of manufacturing an orthopedic component for implantation into a bone and defining an acetabular shell configured for use in a hip replacement surgery, the orthopedic component having a porous bone contacting layer, an interdigitation layer, and an inner layer, the method comprising: determining an elastic modulus of the bone; selecting a thickness of at least one of the porous bone contacting layer, the interdigitation layer, and the inner layer based on the elastic modulus of the bone; and molding the inner layer to the porous bone contacting layer to form at least one of the porous bone contacting layer, the interdigitation layer, and the inner layer to have the selected thickness; wherein the inner layer is formed from an antioxidant stabilized crosslinked ultrahigh molecular weight polyethylene having a thickness of less than six millimeters, the inner layer being configured to receive a femoral component, and the antioxidant stabilized crosslinked ultrahigh molecular weight polyethylene being prepared by a process that includes: combining ultrahigh molecular weight polyethylene with an antioxidant to form a blend; processing the blend to consolidate the blend, wherein the consolidated blend has a melting point; preheating the consolidated blend to a preheat temperature below the melting point of the consolidated blend; and irradiating the preheated consolidated blend while maintaining the preheated consolidated blend at a temperature below the melting point of the consolidated blend; wherein the antioxidant is substantially uniformly distributed throughout the antioxidant stabilized crosslinked ultrahigh molecular weight polyethylene; and wherein the interdigitation layer is defined by a distance over which the antioxidant stabilized crosslinked ultrahigh molecular weight polyethylene of the inner layer infiltrates pores of the porous bone contacting layer.