Implant Devices Constructed with Metallic and Polymeric Components
An intramedullary nail includes a longitudinal core extending along a longitudinal axis from a proximal portion of the nail to a distal portion thereof, the core including a plurality of interlocking features around a circumference thereof and a polymeric casing extending about at least a portion of the circumference of the core including the interlocking features to mechanically interlock the casing and the core, at least a portion of a length of the core being embedded within the casing offset from a longitudinal axis of the nail so that a thickness of casing varies about a circumference of the nail, a maximum thickness of the casing being located at a site at which a polymeric locking element is to be bonded to the nail.
1 . An intramedullary nail, comprising:
a longitudinal core extending along a longitudinal axis from a proximal portion of the nail to a distal portion thereof, the core including a plurality of interlocking features around a circumference thereof; and
a polymeric casing extending about at least a portion of the circumference of the core including the interlocking features to mechanically interlock the casing and the core, at least a portion of a length of the core being embedded within the casing offset from a longitudinal axis of the nail so that a thickness of casing varies about a circumference of the nail, a maximum thickness of the casing being located at a site at which a polymeric locking element is to be bonded to the nail.
2 . The intramedullary nail of claim 1 , wherein the interlocking features include a plurality of recesses formed in the core.
3 . The intramedullary nail of claim 1 , wherein the interlocking features include a plurality of projections extending out of the core into the casing.
4 . The intramedullary nail of claim 1 , wherein the interlocking features include a projection extending out of the core into the casing and a recess formed in the core.
5 . The intramedullary nail of claim 2 , wherein the polymeric material of the casing is received within the recesses such that the casing mechanically interlocks with the core.
6 . The intramedullary nail of claim 1 , wherein the core is formed of a metal.
7 . The intramedullary nail of claim 1 , wherein the casing extends along an entire length of the core.
8 . The intramedullary nail of claim 1 , wherein the casing extends along portions of the nail desired to come into contact with the locking element.
9 . The intramedullary nail of claim 1 , wherein the nail extends along a curved longitudinal axis corresponding to a curvature of a bone into which the nail is to be inserted.
10 . The intramedullary nail of claim 1 , wherein the casing is formed of one of polyetheretherketone, polylactide and UHMWPE.
11 . A system for treating a bone, comprising:
an intramedullary nail, including:
a longitudinal core extending along a longitudinal axis from a proximal portion of the nail to a distal portion thereof, the core including a plurality of interlocking features around a circumference thereof; and
a polymeric casing extending about at least a portion of the circumference of the core including the interlocking features to mechanically interlock the casing and the core, at least a portion of a length of the core being embedded within the casing offset from a longitudinal axis of the nail so that a thickness of casing varies about a circumference of the nail; and
a polymeric locking element bonding with the nail when positioned in contact with a portion of the casing having a maximum thickness and heated such that polymeric materials thereof are welded together.
12 . The system of claim 11 , wherein the locking element includes a shaft having a distal end formed of two angled surfaces increasing a surface of the locking element contacting the intramedullary nail.
13 . (canceled)
14 . The system of claim 11 , wherein the interlocking features include a plurality of recesses formed in the core.
15 . The system of claim 11 , wherein the interlocking features including a plurality of projections extending out of the core into the casing.
16 . The system of claim 11 , wherein the interlocking features including a projection extending out of the core into the casing and a recess formed in the core.
17 . The system of claim 11 , wherein the core is formed of a metal.
18 . The system of claim 11 , wherein the casing extends along an entire length of the core.
19 . The system of claim 11 , wherein the casing extends along portions of the nail desired to come into contact with the locking element.
20 . The system of claim 11 , wherein the nail extends along a curved longitudinal axis corresponding to a curvature of a bone into which the nail is to be inserted.
21 . The system of claim 11 , wherein the casing is formed of one of polyetheretherketone, polylactide and UHMWPE.