US 12,251,318 B2
Surgical implant device incorporating a lattice volume and associated method of manufacture
Scott Alan Rucker, Austin, TX (US); Joseph Virgil Thompson, Round Rock, TX (US); Gregory N. Glazner, Austin, TX (US); and Trace Cawley, Austin, TX (US)
Assigned to Kyocera Medical Technologies, Inc., Redlands, CA (US)
Filed by Kyocera Medical Technologies, Inc., Redlands, CA (US)
Filed on Oct. 16, 2020, as Appl. No. 17/072,111.
Prior Publication US 2022/0117753 A1, Apr. 21, 2022
Int. Cl. A61F 2/44 (2006.01); A61F 2/30 (2006.01)
CPC A61F 2/4455 (2013.01) [A61F 2/3094 (2013.01); A61F 2/442 (2013.01); A61F 2002/30011 (2013.01); A61F 2002/30985 (2013.01); A61F 2002/4435 (2013.01); A61F 2310/00011 (2013.01)] 10 Claims
OG exemplary drawing
 
1. A surgical implant device, comprising:
an upper solid surface defining an upper bone contacting surface including an entire upper surface of the surgical implant device; and
a lower solid surface defining a lower bone contacting surface including an entire lower surface of the surgical implant device; and
a lattice structure disposed between the upper solid surface and the lower solid surface, wherein a first layer of the lattice structure fills a first full cross-section of the lattice structure and has a first thickness, the first layer comprising a first plurality of struts that define a first plurality of voids adjacent to one of the upper solid surface or the lower solid surface within an interior of the surgical implant device, a second layer of the lattice structure fills a second full cross-section of the lattice structure and has a second thickness, the second layer comprising a second plurality of struts that define a second plurality of voids adjacent to the other of the upper solid surface or the lower solid surface within the interior of the surgical implant device, and a third layer of the lattice structure fills a third full cross-section of the lattice structure and has a third thickness, the third layer comprising a third plurality of struts that define a third plurality of voids remote from each of the upper solid surface and the lower solid surface and within the interior of the surgical implant device, wherein each of the first plurality of struts and each of the second plurality of struts has an average cross-sectional diameter that is smaller than an average cross-sectional diameter of each of the third plurality of struts, wherein each of the first plurality of voids and each of the second plurality of voids has an average internal dimension that is smaller than an average internal dimension of each of the third plurality of voids,
wherein the first plurality of struts and the first plurality of voids are disposed between and coupled between one of the upper solid surface or the lower solid surface and/to the third plurality of struts and the third plurality of voids, and the second plurality of struts and the second plurality of voids are disposed between and coupled between the other of the upper solid surface or the lower solid surface and/to the third plurality of struts and the third plurality of voids such that the third layer of the lattice structure separates the first layer and the second layer of the lattice structure throughout the lattice structure, and
wherein each of the first plurality of struts and the first plurality of voids and the second plurality of struts and the second plurality of voids has an overall material density that is approximately equal to the third plurality of struts and the third plurality of voids.