Three-dimensional lattice structures for implants
Inventors
Laine, Christopher • Helmar, Ian • Diehl, Lucas • Tinley, Jason • Chappuis, Kevin D. • Sullivan, John F.
Assignees
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Publication Number
US-12036126-B2
Publication Date
2024-07-16
Expiration Date
Abstract
The three-dimensional lattice structures disclosed herein have applications including use in medical implants. Some examples of the lattice structure are structural in that they can be used to provide structural support or mechanical spacing. In some examples, the lattice can be configured as a scaffold to support bone or tissue growth. Some examples can use a repeating modified rhombic dodecahedron or radial dodeca-rhombus unit cell. The lattice structures are also capable of providing a lattice structure with anisotropic properties to better suit the lattice for its intended purpose.
Core Innovation
An implant is described that includes a three-dimensional lattice structure configured to extend between two adjacent bony structures and provide sole mechanical spacing between the two adjacent bony structures. The lattice structure includes a plurality of unit cells, and each unit cell comprises a plurality of sub-unit cells. Each sub-unit cell includes a node located within a volume of the sub-unit cell, a plurality of struts extending radially from the node to define boundaries of the sub-unit cell, and a plurality of fluidly interconnected openings.
At least one unit cell comprises a rhombic dodecahedron geometric shape, and at least one unit cell is configured to have a rhombic dodecahedron geometric shape having an elongated shape along X and Y axes. The described lattice geometry is based on unit cells, sub-unit cells, nodes, struts, and openings, and the boundaries of the sub-unit cells are defined by radially extending struts.
The document further specifies node geometry in an implant that uses a square bipyramid node with eight node faces. In that implant, a first peak faces a top portion of the cuboid volume and a second peak faces a bottom portion of the cuboid volume, and at least one opening is specified with a cross-sectional area of 7 square millimeters along its cross-sectional area.
Claims Coverage
The document provides three independent claims. The claim coverage centers on a three-dimensional lattice implant configured to provide sole mechanical spacing, with unit cells comprising sub-unit cells defined by a node, radially extending struts, and fluidly interconnected openings, and with additional geometric constraints on the unit-cell and node shapes and on opening area.
Sole mechanical spacing lattice between adjacent bony structures
A three-dimensional lattice structure configured to extend between two adjacent bony structures and provide sole mechanical spacing between the two adjacent bony structures.
Unit cell with nodes, radially extending struts, and fluidly interconnected openings
A lattice structure comprising a plurality of unit cells, each unit cell comprising a plurality of sub-unit cells, where each sub-unit cell includes a node located within a volume, a plurality of struts extending radially from the node and defining boundaries of the sub-unit cell, and a plurality of fluidly interconnected openings.
Rhombic dodecahedron unit cell geometry
At least one unit cell from among the plurality of unit cells comprises a rhombic dodecahedron geometric shape.
Elongated rhombic dodecahedron along X and Y axes
At least one unit cell comprises a rhombic dodecahedron geometric shape having an elongated shape along X and Y axes.
Square bipyramid node with face/peak orientation in a cuboid volume
The node comprises a square bipyramid with eight node faces and a square plane parallel to a face of a cuboid volume and is centrally located within the volume of the unit cell, where a first peak faces a top portion of the cuboid volume and a second peak faces a bottom portion of the cuboid volume.
Strut coupling from a node face to a corner of the sub-unit cell volume
A first strut from the plurality of struts is coupled to a first node face and configured to extend from the node face to a corner of the volume of the sub-unit cell.
Opening cross-sectional area constraint
At least one opening from among the plurality of interconnected openings comprises an area of 7 square millimeters along its cross-sectional area.
Across the three independent claims, the core coverage is an implant lattice that provides sole mechanical spacing between adjacent bony structures using unit cells and sub-unit cells with nodes, radially extending struts, and fluidly interconnected openings, with additional requirements for rhombic dodecahedron geometry, a square bipyramid node with specified peak orientation, and a specified opening area.
Stated Advantages
Not explicitly described in patent.
Documented Applications
Not explicitly described in patent.
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